Patent ID: 6632894
Filing Date: 2003-10-14
Classification: B01J,C08F,Y10S

Abstract:
A process to produce a catalyst composition, said process comprising contacting an organometal compound, an organoaluminum compound, and an oxide matrix composition to produce said catalyst composition,wherein said organometal compound has the following general formula: (X1)(X2)(X3)(X4)M1 wherein M1 is selected from the group consisting of titanium, zirconium, and hafnium; wherein (X1) is independently selected from the group consisting of cyclopentadienyls, indenyls, fluorenyls, substituted cyclopentadienyls, substituted indenyls, and substituted fluorenyls; wherein substituents on said substituted cyclopentadienyls, substituted indenyls, and substituted fluorenyls of (X1) are selected from the group consisting of aliphatic groups, cyclic groups, combinations of aliphatic and cyclic groups, silyl groups, alkyl halide groups, halides, organometallic groups, phosphorus groups, nitrogen groups, silicon, phosphorus, boron, germanium, and hydrogen; wherein at least one substituent on (X1) can be a bridging group which connects (X1) and (X2); wherein (X3) and (X4) are independently selected from the group consisting of halides, aliphatic groups, substituted aliphatic groups, cyclic groups, substituted cyclic groups, combinations of aliphatic groups and cyclic groups, combinations of substituted aliphatic groups and cyclic groups, combinations of aliphatic groups and substituted cyclic groups, combinations of substituted aliphatic groups and substituted cyclic groups, amido groups, substituted amido groups, phosphido groups, substituted phosphido groups, alkyloxide groups, substituted alkyloxide groups, aryloxide groups, substituted aryloxide groups, organometallic groups, and substituted organometallic groups; wherein (X2) is selected from the group consisting of cyclopentadienyls, indenyls, fluorenyls, substituted cyclopentadienyls, substituted indenyls, substituted fluorenyls, halides, aliphatic groups, substituted aliphatic groups, cyclic groups, substituted cyclic groups, combinations of aliphatic groups and cyclic groups, combinations of substituted aliphatic groups and cyclic groups, combinations of aliphatic groups and substituted cyclic groups, combinations of substituted aliphatic groups and substituted cyclic groups, amido groups, substituted amido groups, phosphido groups, substituted phosphido groups, alkyloxide groups, substituted alkyloxide groups, aryloxide groups, substituted aryloxide groups, organometallic groups, and substituted organometallic groups; wherein substituents on (X2) are selected from the group consisting of aliphatic groups, cyclic groups, combinations of aliphatic groups and cyclic groups, silyl groups, alkyl halide groups, halides, organometallic groups, phosphorus groups, nitrogen groups, silicon, phosphorus, boron, germanium, and hydrogen; wherein at least one substituent on (X2) can be a bridging group which connects (X1) and (X2); wherein said organoaluminum compound has the following general formula: Al(X5)n(X6)3âˆ’n wherein (X5) is a hydrocarbyl having from 1 to about 20 carbon atoms; wherein (X6) is a halide, hydride, or alkoxide; wherein â€œnâ€  is a number from 1 to 3 inclusive; and wherein said oxide matrix composition is produced by the process comprising: 1) substantially decomposing or exfoliating at least one layered mineral to produce residual mineral components; wherein the layered mineral is a clay, clay mineral, or ion exchanging compound having a layered crystal structure; 2) contacting the residual mineral components and at least one oxide precursor compound to produce a first mixture; wherein the oxide precursor compound is selected from the group consisting of a silica source, alumina source, phosphate source; or combinations thereof; 3) subjecting the first mixture to such conditions to form a gel or precipitate; and 4) drying the gel or precipitate, and then calcining the gel or precipitate at a temperature in a range of about 150Â° C. to about 800Â° C. to produce the oxide matrix composition.