# Patent

## Title
Polymers, method of producing the same, and articles made therefrom

## Abstract

A virgin granular polymer comprising polymer particles wherein at least 90% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1, and further wherein the virgin granular polymer has an I21 less than or equal to 70 and/or further wherein at least 90% by weight of the granular polymer particles, have a density that is within two standard deviations of a mean density of the granular polymer, the ratio of the standard deviation of the mean density of the granular polymer to the mean density of the granular polymer is less than 0.002 and the ratio of the standard error of a linear fit to the mean of the density is less than 0.001, and further wherein the virgin granular polymer has an I21 less than or equal to 70 is provided.

## Background
FIELD OF THE INVENTION
The invention relates to polymers, method of producing the polymer and articles made therefrom. More particularly, the invention relates to polymers having a narrow composition distribution across particle size and providing low gels and good visual appearance when used to make articles.
BACKGROUND OF THE INVENTION
Fluidized bed and slurry polymerization systems, particularly staged reactor systems, can suffer from significant variation in the polymer properties of varying particle size fractions. Large variations in polymer properties across particle size can lead to difficulty in mixing the different particles during, for example, pelletization. If all of the granular particles are of similar properties, mixing will occur readily. However, if one or more fractions of particles are of substantially different molecular weight or density, melting during a pelleting operation will not be uniform. Nonuniform pelletization can, in turn, result in:

    
    
        1. “unmelts”—pellets that still have some areas of relatively undispersed granular which may cause gels or imperfections in finished articles;
        2. very high gel count pellets which can occur when granular particles are of significantly different viscosity when melted, i.e. a large molecular weight variation across particles, leading to very high gel counts in thin sheets or films; and
        3. an inability to use the resin in granular form as exiting from the final reactor due to substantial differences in molecular weight or density that prevent direct granule users, such as rotational molders, or fabricating extruders, such as blow molders, from utilizing the product due to poor mixing and high gel counts.
    
    


Such variation in polymer properties across particle size fractions occur more significantly when dual or linked reactors are used in the polymerization process, giving an even greater potential for formation of polymer granules with widely divergent properties. For example, if the polymer exiting the first reactor substantially differs in polymer properties across the particle size range, this disparity will continue and be further exacerbated in the second reactor.
To address this situation, the current approach is to employ very small catalyst particles which will produce very small polymer particles. Once used in applications, these very small polymer particles do not appear as a gel even with broad compositional distributions.
A catalyst system useful across a broad range of catalyst particle size and which produces polymers that may be compounded to produce very low gel counts would be very desirable.
SUMMARY OF THE INVENTION
The instant invention is a polymer, a method of producing the polymer and articles made from the polymer.
In one embodiment, the instant invention provides a virgin granular polymer comprising polymer particles wherein at least 90% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1, and further wherein the virgin granular polymer has an I21 less than or equal to 70.
In another embodiment, the instant invention provides a virgin granular polymer comprising polymer particles wherein at least 90% by weight of the granular polymer particles, have a density that is within two standard deviations of a mean density of the granular polymer, the ratio of the standard deviation of the mean density of the granular polymer to the mean density of the granular polymer is less than 0.002 and the ratio of the standard error of a linear fit to the mean of the density is less than 0.001, and further wherein the virgin granular polymer has an I21 less than or equal to 70.
In another embodiment, the invention provides a reaction product of polymerizing at least one olefin monomer in the presence of: (A) at least one catalyst precursor produced by contacting a Group 4 metal compound with one or more Titanium compounds selected from the group of TiCl3 (Al-activated or hydrogen-reduced), and Ti(OR)4 where R is ethyl, isopropyl or n-butyl in the presence of an alcohol solution comprising at least one C2-C4 alcohol and at least one of MgCl2 and magnesium compounds which form MgCl2 in the presence of the alcohol solution to form a catalyst precursor solution, forming said catalyst precursor solution into solid particles and subsequently halogenating the solid particles; and (B) at least one co-catalyst; wherein the reaction product comprises a granular polymer comprised of polymer particles and further wherein at least 90% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1.
In another embodiment, the instant invention provides a reaction product of polymerizing at least one monomer, in the gas phase, in the presence of: (A) at least one catalyst precursor produced by contacting a Group 4 metal compound with one or more Titanium compounds selected from the group of TiCl3 (Al-activated or hydrogen-reduced), and Ti(OR)4 where R is ethyl, isopropyl or n-butyl in the presence of an alcohol solution comprising at least one C2-C4 alcohol and at least one of MgCl2 and magnesium compounds which form MgCl2 in the presence of the alcohol solution to form a catalyst precursor solution, forming said catalyst precursor solution into solid particles and subsequently halogenating the solid particles; and (B) at least one co-catalyst; wherein the reaction product comprises a granular polymer comprised of polymer particles and further wherein at least 90% by weight of the granular polymer particles, have a density that is within two standard deviations of a mean density of the granular polymer, the ratio of the standard deviation of the mean density of the granular polymer to the mean density of the granular polymer is less than 0.002 and the ratio of the standard error of a linear fit to the mean of the density is less than 0.001.
In an alternative embodiment, the instant invention provides a virgin granular polymer and reaction product, in accordance with any of the preceding embodiments, except that at least 95% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1.
In an alternative embodiment, the instant invention provides a virgin granular polymer and reaction product, in accordance with any of the preceding embodiments, except that at least 93% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1.
In an alternative embodiment, the instant invention provides a virgin granular polymer and reaction product, in accordance with any of the preceding embodiments, except that at least 95% by weight of the granular polymer particles, have a density that is within two standard deviations of a mean density of the granular polymer, the ratio of the standard deviation of the mean density of the granular polymer to the mean density of the granular polymer is less than 0.002 and the ratio of the standard error of a linear fit to the mean of the density is less than 0.001.
In an alternative embodiment, the instant invention provides a virgin granular polymer and reaction product, in accordance with any of the preceding embodiments, except that at least 93% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1.
In an alternative embodiment, the instant invention provides a virgin granular polymer and reaction product, in accordance with any of the preceding embodiments, except that the granular polymer is produced in a two stage linked reactor system.
In an alternative embodiment, the instant invention provides a virgin granular polymer and reaction product, in accordance with any of the preceding embodiments, except that the granular polymer is produced in a one stage reactor system.
In an alternative embodiment, the instant invention provides a virgin granular polymer and reaction product, in accordance with any of the preceding embodiments, except that the granular polymer is produced in a fluidized bed reactor system.
In an alternative embodiment, the instant invention provides a virgin granular polymer and reaction product, in accordance with any of the preceding embodiments, except that the granular polymer is produced in a slurry reactor system.
In an alternative embodiment, the instant invention provides a virgin granular polymer consisting essentially of polymer particles wherein at least 90% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1, and further wherein the virgin granular polymer has an I21 less than or equal to 70.
In another embodiment, the instant invention provides a virgin granular polymer consisting essentially of polymer particles wherein at least 90% by weight of the granular polymer particles, have a density that is within two standard deviations of a mean density of the granular polymer, the ratio of the standard deviation of the mean density of the granular polymer to the mean density of the granular polymer is less than 0.002 and the ratio of the standard error of a linear fit to the mean of the density is less than 0.001, and further wherein the virgin granular polymer has an I21 less than or equal to 70.


DETAILED DESCRIPTION OF THE INVENTION
The terms “catalyst” and “catalyst composition” as used herein, refer to transition metal compounds, or mixtures thereof, that are useful in catalyzing the polymerization of addition polymerizable monomers, generally in combination with one or more cocatalysts or activator compounds. Preferred catalysts are mixtures or complexes of non-metallocene transition metal compounds and magnesium compounds, such as magnesium chloride compounds, alternatively referred to as Ziegler Natta catalysts or Ziegler Natta type catalysts.
The term “procatalyst” as used herein means a catalyst composition ready to be injected or fed into a polymerization reactor and that is activated to an active polymerization catalyst within the polymerization reactor by an additional component, a cocatalyst, such as an aluminum alkyl cocatalyst.
The terms “precursor” and “catalyst precursor” as used herein mean a portion of the catalyst composition containing the transition metals that is subjected to an additional reaction step to convert it into a procatalyst.
The term “virgin granular polymer” means a granular polyolefin polymer exiting a polymerization reactor with no further processing, such as grinding, pelletizing, extruding or the like.
The term “granular polymer” means a polymer produced in a fluidized bed or slurry polymerization reactor and which exits the reactor in a granular or particle form.
The term “mean” means an unweighted average.
The instant invention is a virgin granular polymer, a reaction product, articles made therefrom, and methods for making such articles.
The polymer according to a first aspect of the present invention is a virgin granular polymer comprising polymer particles wherein at least 90% by weight of the granular polymer particles have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1, and further wherein the virgin granular polymer has an I21 less than or equal to 30. All individual values and subranges from greater than 90% by weight are included herein and disclosed herein; for example, the weight percent of the granular polymer particles having the ascribed characteristics may be from a lower limit of 90, 91, 92, 93, or 94 weight percent to an upper limit of 91, 92, 93, 94, 95, 96, 97, 98, 99 or 100 weight percent, based on the total weight of the virgin granular polymer. For example, the weight percent of the granular polymer particles having the ascribed characteristics may be in the range of from 90 to 95 weight percent, or in the alternative from 91 to 98 weight percent, or in the alternative, from 95 to 99 weight percent, or in the alternative from 93 to 99 weight percent, or in the alternative, from 94 to 97 weight percent, based on the total weight of the virgin granular polymer.
Further, the at least 90% by weight of the granular polymer particles have an I21 wherein the ratio of the standard deviation of I21 to the mean of the I21 of the granular polymer is less than 0.2. All individual values from less than 0.2 are included herein and disclosed herein; for example, the ratio of the standard deviation of I21 to the mean of the I21 of the granular polymer may be from an upper limit of 0.02. 0.04, 0.06, 0.08, 0.1, 0.13, 0.15, 0.17, 0.19 or 0.2.
Further, the at least 90% by weight of the granular polymer particles have an I21 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1. All individual values from less than 0.1 are included herein and disclosed herein; for example, the ratio of the standard error of a linear fit to the mean of the granular polymer may be from an upper limit of 0.02, 0.04, 0.06, 0.08, or 0.1.
Further, the at least 90% by weight of the granular polymer particles have an I21 less than or equal to 70. All individual values of less than or equal to 70 are included herein and disclosed herein; for example, I21 may be less than or equal to 70, or in the alternative less than or equal to 50, or in the alternative less than or equal to 40, or in the alternative less than or equal to 30, or in the alternative less than or equal to 20, or in the alternative less than or equal to 10, or in the alternative less than or equal to 8, or in the alternative less than or equal to 4.
In one embodiment, the virgin granular polymer is a polyethylene.
In a further embodiment, the virgin granular polymer is a polyethylene produced in a gas phase or slurry polymerization process.
The polymer according to a second aspect of the present invention is a virgin granular polymer comprising polymer particles wherein at least 90% by weight of the granular polymer particles a density that is within two standard deviations of a mean density of the granular polymer, the ratio of the standard deviation of the mean density of the granular polymer to the mean density of the granular polymer is less than 0.002 and the ratio of the standard error of a linear fit to the mean of the density is less than 0.001, and further wherein the virgin granular polymer has an I21 less than or equal to 70. All individual values and subranges from greater than 90% by weight are included herein and disclosed herein; for example, the weight percent of the granular polymer particles having the ascribed characteristics may be from a lower limit of 90, 91, 92, 93, or 94 weight percent to an upper limit of 91, 92, 93, 94, 95, 96, 97, 98, 99 or 100 weight percent, based on the total weight of the virgin granular polymer. For example, the weight percent of the granular polymer particles having the ascribed characteristics may be in the range of from 90 to 95 weight percent, or in the alternative from 91 to 98 weight percent, or in the alternative, from 95 to 99 weight percent, or in the alternative from 93 to 99 weight percent, or in the alternative, from 94 to 97 weight percent, based on the total weight of the virgin granular polymer.
Further, the at least 90% by weight of the granular polymer particles have a density wherein the ratio of the standard deviation of the mean density of the granular polymer to the mean density of the granular polymer is less than 0.002. All individual values from less than 0.002 are included herein and disclosed herein; for example, the ratio of the standard deviation of the mean density of the granular polymer to the mean density of the granular polymer may be from an upper limit of 0.0002. 0.0004, 0.0006, 0.0008, 0.001, 0.0013, 0.0015, 0.0017, 0.0019 or 0.002.
Further, the at least 90% by weight of the granular polymer particles have a density and the ratio of the standard error of a linear fit to the mean of the density is less than 0.001. All individual values from less than 0.001 are included herein and disclosed herein; for example, the ratio of the standard error of a linear fit to the mean of the density may be from an upper limit of 0.0002, 0.0004, 0.0006, 0.0008, or 0.001.
Further, the at least 90% by weight of the granular polymer particles have an I21 less than or equal to 70. All individual values of less than or equal to 70 are included herein and disclosed herein; for example, I21 may be less than or equal to 70, or in the alternative less than or equal to 60, or in the alternative less than or equal to 50, or in the alternative less than or equal to 40, or in the alternative less than or equal to 30, or in the alternative less than or equal to 10, or in the alternative less than or equal to 8, or in the alternative less than or equal to 4.
The polymer according to a third aspect of the present invention is a reaction product of polymerizing at least one olefin monomer in the presence of: (A) at least one catalyst precursor produced by contacting a Group 4 metal compound with one or more Titanium compounds selected from the group of TiCl3 (Al-activated or hydrogen-reduced), and Ti(OR)4 where R is ethyl, isopropyl or n-butyl in the presence of an alcohol solution comprising at least one C2-C4 alcohol and at least one of MgCl2 and magnesium compounds which form MgCl2 in the presence of the alcohol solution to form a catalyst precursor solution, forming said catalyst precursor solution into solid particles and subsequently halogenating the solid particles; and (B) at least one co-catalyst; wherein the reaction product comprises a granular polymer comprised of polymer particles and further wherein at least 90% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1. All individual values and subranges from greater than 90% by weight of the granular polymer particles are included herein and disclosed herein; for example, the weight percent of the granular polymer particles having the ascribed characteristics may be from a lower limit of 90, 91, 92, 93, or 94 weight percent to an upper limit of 91, 92, 93, 94, 95, 96, 97, 98, 99 or 100 weight percent, based on the total weight of the granular polymer. For example, the weight percent of the granular polymer particles having the ascribed characteristics may be in the range of from 90 to 95 weight percent, or in the alternative from 91 to 98 weight percent, or in the alternative, from 95 to 99 weight percent, or in the alternative from 93 to 99 weight percent, or in the alternative, from 94 to 97 weight percent, based on the total weight of the granular polymer.
The polymer according to a fourth aspect of the present invention is a reaction product of polymerizing at least one monomer, in the gas phase, in the presence of: (A) at least one catalyst precursor produced by contacting a Group 4 metal compound with one or more Titanium compounds selected from the group of TiCl3 (Al-activated or hydrogen-reduced), and Ti(OR)4 where R is ethyl, isopropyl or n-butyl in the presence of an alcohol solution comprising at least one C2-C4 alcohol and at least one of MgCl2 and magnesium compounds which form MgCl2 in the presence of the alcohol solution to form a catalyst precursor solution, forming said catalyst precursor solution into solid particles and subsequently halogenating the solid particles; and (B) at least one co-catalyst; wherein the reaction product comprises a granular polymer comprised of polymer particles and further wherein at least 90% by weight of the granular polymer particles, have a density that is within two standard deviations of a mean density of the granular polymer, the ratio of the standard deviation of the mean density of the granular polymer to the mean density of the granular polymer is less than 0.002 and the ratio of the standard error of a linear fit to the mean of the density is less than 0.001. All individual values and subranges from greater than 90% by weight of the granular polymer particles are included herein and disclosed herein; for example, the weight percent of the granular polymer particles having the ascribed characteristics may be from a lower limit of 90, 91, 92, 93, or 94 weight percent to an upper limit of 91, 92, 93, 94, 95, 96, 97, 98, 99 or 100 weight percent, based on the total weight of the granular polymer. For example, the weight percent of the granular polymer particles having the ascribed characteristics may be in the range of from 90 to 95 weight percent, or in the alternative from 91 to 98 weight percent, or in the alternative, from 95 to 99 weight percent, or in the alternative from 93 to 99 weight percent, or in the alternative, from 94 to 97 weight percent, based on the total weight of the granular polymer.
In one embodiment, the inventive virgin granular polymer is a combination of two or more of the embodiments described herein.
In one embodiment, the reaction product is a combination f tow or more of the embodiments described herein.
Catalyst precursors useful in the invention include those with no internal electron donors. The catalyst precursors may comprise substantially spheroidal shaped particles of a magnesium halide containing precursor, the particles having an average size (D50) of from 10 to 70 microns, from 15 to 50 microns, or from 20 to 35 microns, having been produced via spray drying from a nominally neutral acidity feedstock. The catalyst precursor may be produced by: a) providing a liquid composition comprising i) a magnesium halide compound or magnesium compound that is convertible to magnesium halide via halogenation, ii) an alcoholic solvent or diluent, iii) at least two transition metal compounds wherein the transition metals are selected from the metals of Groups 3-10 and of the Periodic Table of the Elements and wherein one of the metals is Titanium and the other metal is Zirconium or Hafnium or both, iv) optionally a filler wherein the acidity of the liquid composition is adjusted to essentially neutral by adjusting the composition of either the Titanium compound or the magnesium compound that is convertible to magnesium chloride; b) spray-drying the composition in a closed cycle spray drier to form a spray-dried particle; and c) collecting the resulting solid particles which are a precursor powder. Representative magnesium compounds that convert to MgCl2 in the presence of the alcohol solution include magnesium alkoxides and magnesium alkyl carbonates.
The spray-dried procatalyst particles may be combined with a cocatalyst to form an active catalyst composition. The activation may occur prior to or simultaneously with, or after contacting with the monomer or monomers to be polymerized. In some embodiments of the present invention, the procatalyst is partially or fully activated outside the polymerization reactor by contacting the procatalyst with a portion of the cocatalyst in an inert liquid hydrocarbon as disclosed in U.S. Pat. Nos. 6,187,866 and 6,617,405, the disclosures of which are incorporated herein by reference. After contacting the procatalyst composition with the cocatalyst, the hydrocarbon solvent may be removed by drying or, preferably, the catalyst composition may be directly fed to the polymerization reactor where the activation is completed with additional amounts of the same or a different cocatalyst.
Additional precursor, procatalysts and catalysts useful in the preparing the inventive virgin granular polymers are described in copending application U.S. application Ser. No. 12/759,515 filed on Apr. 13, 2010, the disclosure of which is incorporated herein by reference.
The virgin granular polymers of the present invention are useful in a variety of applications ranging from blow molding products to stretch tapes. The inventive virgin granular polymers are useful in direct applications such as rotomolding, blowmolding or sheet formation and are particularly amenable to the production of very high molecular weight polymers that may be very difficult to pelletize for homogeneity, i.e. polymers with high load melt indices (I21) in the 0.1 to 3 range.
The inventive virgin granular polymers may be produced in existing fluidized bed or slurry reaction systems, and may be produced using single or multiple reactor systems. The inventive virgin granular polymers may be produced, for example, in the reactor systems disclosed in WO2008US87581 and WO2008US87378, the disclosures of which are incorporated herein by reference
Variation in the inventive virgin granular polymer properties are controlled within the limits prescribed by measurement method precision. Resin Density, for example, may be precisely measured according to ASTM D792. Table 1 provides the Standard Deviation (SD) and r value of resin density measurements taken according to ASTM D792 on a test high density polyethylene.











TABLE 1








Standard Deviation (SD)





of multiple tests



Method
within one laboratory
r value = 2.8 * SD









ASTM D792
0.0008
0.0022










ASTM D792 defines the repeatability or repeatability index, r, as: r=2.8·(SD). A measurement on a material has repeatability if two test results obtained within one laboratory differ by the r value or less for that material. The r value is the critical difference between two test results for the same material, obtained by the same operator using the same equipment on the same day in the same laboratory. Thus, all particle size fractions of the inventive virgin granular polymer should have a density within ±0.0022 g/cc of each other. In such instance, the virgin granular polymer can be said to an equivalent density across all polymer particle fractions.
In like manner, for I21, I5 and I2 there are known levels of variation that are the result of the test itself independent of the actual normal variation that may occur in any continuous process. Again, to provide for the optimum granular resin performance, it is desired that >90% by weight and preferably >95% by weight of the granular resin has melt flow properties that are within this known level of variation in measurement.
In particular, for very high molecular weight polymers, the I21 value is generally measured using ASTM standard 1238 D, Procedure A (cut-off). Repeatability indices are not given for I21, only for I2, however one of ordinary skill in the art would anticipate that the repeatability for I21 would be similar to that for I2. Table 2 below provides the repeatability, r, (i.e., precision) indices for I2 as specified in ASTM 1238D, Procedure A, wherein Standard Deviation=SD.













TABLE 2










Low
High







I2
I2


Material/
Mean
SD between
Repeatability =
% of
(g/10 min)
(g/10 min)


Condition
I2 (g/10 min)
Labs
2.83 * SD
Value*
Value
Value





















Polyethylene
0.27
0.022
0.062
23.1
0.208
0.332


190/2.16


Polyethylene
0.4
0.038
0.108
26.9
0.292
0.508


190/2.16


Polyethylene
2.04
0.079
0.224
11.0
1.816
2.264


190/2.16





*Calculated as r value divided by average I2 multiplied by 100.






Because the actual measured quantity, (grams/10 minutes (g/10 min)) flowing through a die of a prescribed size at a prescribed temperature is not fully representative of the actual molecular weight of the polymer, the natural logarithm (“ln” herein) of the I21, I5 or I2 is used as this is a better predictor of actual molecular weight of the polymer. In general, the change in ln(I21) is representative of the change in number average molecular weight whereas the change in ln(I2) is representative of the change in weight average molecular weight.
EXAMPLES
The following examples illustrate the present invention but are not intended to limit the scope of the invention.
Inventive Examples
Precursor and Procatalyst Preparation
The catalyst precursor solution used in each of the polymerization process, Inventive Examples 1-4 below, was prepared as follows:
Under inert reaction conditions, the components shown in Table 3 were charged to a solution preparation vessel.










TABLE 3







Feedstock Charge



















Ethanol, kg
1000



MgCl2, kg
50.34



TiCl3 AA, kg
20.34



HfCl4, kg
33.64



CAB-O-SIL TM TS-610, kg
70.00










The ethanol was charged first followed by MgCl2, HfCl4 and TiCl3 (AA). Amounts listed were aim values, some slight losses occurred although the amounts given in Table 1 are all within 5% by weight of the amount actually added. The ethanol used was specially denatured ethanol from Brüggemann Chemical U.S., Inc. (Newtown Square, Pa.) containing about 0.5% by weight of toluene and <100 ppm water. Magnesium chloride was obtained from SRC, Inc. (Cleveland, Ohio), Hafnium Tetrachloride (containing up to 1 wt % Zirconium) from ATI Wah-Chang (Albany, Oreg.) and aluminum activated titanium trichloride from W.R. Grace & Co. CAB-O-SILTM TS-610 (which is a filler) was obtained from the Cabot Corporation.
The mixture was stirred at 35 to 50° C. under a nitrogen blanket for about 8 hours prior to the start of spray drying. The spray drying process produced a catalyst precursor powder. A 2.5 meter Gea Niro Rotary Atomizer Type FS-15 atomizer wheel (available from Gea Niro, Søborg, Denmark) was used. Atomizer speed was adjusted to obtain an average particle size of the catalyst precursor of about 30 microns. Inlet temperature was adjusted to achieve an outlet temperature between 105 and 110° C. and the feedstock was spray dried at a rate of 100 to 150 kg/hr.
Particle size distribution in the catalyst precursor powder was determined using a Malvern Mastersizer 2000 particle size analyzer with heptane as the dispersant. The General Purpose (Spherical) particle model was used to calculate particle size. Sonication was utilized (50% power, 30 to 60 seconds) to break up any agglomerates that might have formed in the sampling process. Table 4 lists the particle size distribution of the catalyst precursor powder by percent by volume.










TABLE 4







Particle Size,




Microns
Volume %



















0.55
0.07



0.63
0.1



0.724
0.12



0.832
0.15



0.955
0.18



1.096
0.21



1.259
0.23



1.445
0.24



1.66
0.22



1.905
0.21



2.188
0.23



2.512
0.3



2.884
0.45



3.311
0.7



3.802
1.05



4.365
1.49



5.012
1.95



5.754
2.4



6.607
2.76



7.586
2.99



8.71
3.07



10
3.02



11.482
2.91



22.909
4.63



26.203
5.58



30.2
6.52



34.674
7.26



39.811
7.64



45.709
7.52



52.481
6.88



60.256
5.8



69.183
4.45



79.433
3.03



91.201
1.75



104.713
0.73



120.226
0.11










The catalyst precursor powder was then dispersed in isopentane to form a catalyst precursor powder solution. The halogenation agent, ethylaluminum sesquichloride (EASC), was then added to the catalyst precursor powder solution at a 2.0 “Cl to ethoxide” molar ratio to form a procatalyst slurry. Ethoxide as used herein means free ethanol remaining in the spray dried catalyst precursor and ethoxide ligands present, for example, on the Hf, Ti and/or Zr components. Ethoxide content is measured as ethanol after the catalyst precursor is contacted with acidified water (i.e., HCl added to obtain a pH of about 1). A sample of the liquid phase was then injected into a gas chromatograph and ethanol content determined. The precursor prior to halogenation had an average ethoxide content of about 25 wt % (ranging from 24 to 27 wt % in a number of measurements).
The precursor slurry was then mixed at 50° C. for one hour, and the solids then allowed to settle. The supernatant liquid was decanted, an additional volume of isopentane was added, and this washing step was repeated two additional times.
HYDROBRITE 380 mineral oil (available from Sonneborn, LLC, Mahwah, N.J.) was then added to the solids remaining following the washing process to produce a slurry of procatalyst. Vacuum was drawn on the procatalyst slurry for approximately one hour to evaporate any isopentane remaining following the washing process.
The catalyst precursor for use in the polymerization process, Inventive Example 5 below, was prepared in the same manner as that described above for preparation of the precursor for use in Inventive Examples 1-4 with the following exceptions: Feedstock: Titanium tetraisopropylate was used at the same molar ratio to Magnesium and Hafnium instead of the Titanium Trichloride.
Spray Drying: The spray dryer was a Gea Niro MOBILE MINOR spray dryer (available from Gea Niro, Søborg, Denmark) using the vaned atomizer wheel. Atomizer speed was adjusted to obtain particles having a D50 of about 25 microns and was approximately 34,000 RPM.
Feedrate: Feedrate was adjusted to maintain a 105 to 110° C. outlet temperature. Average feed rate was  ̃100 grams/hour.
Particle size distribution: A narrower particle size distribution was obtained. Particle Size was measured using an LA-950 particle size analyzer (which utilizes software containing both ISO 13320 and USP 429 calculation) available from Horiba Ltd with heptane as the diluent.
Table 5 provides the particle size distribution by volume percent for the catalyst precursor powder for Inventive Example 5.










TABLE 5







Size Microns
Volume %



















4.472
0



5.122
0



5.867
0.124



6.72
0.22



7.697
0.386



8.816
0.665



10.097
1.118



11.565
1.854



13.246
2.977



15.172
4.578



17.377
6.655



19.904
9.007



22.797
11.169



26.111
12.478



29.907
12.378



34.255
10.821



39.234
8.355



44.938
5.855



51.471
3.91



58.953
2.547



67.523
1.648



77.339
1.03



88.583
0.642



101.46
0.412



116.21
0.274



133.1
0.2



152.45
0.159



174.6
0.136



200
0.126



229
0.131



262.4
0.144










The catalyst precursor ethoxide content was about 25 wt %. The catalyst precursor for Inventive Example 5 was converted into a procatalyst using the same procedure as that used to prepare the procatalysts used for Inventive Examples 1-4.
Polymerization Processes and Polymers
Inventive Examples 1-5
For Inventive Example 1 the polymerization reaction was effected in the first reactor of the dual reactor system as described in WO2008US87581 and WO2008US87378, the disclosures of which are incorporated herein by reference. That is, the product of the first reactor was not further subjected to polymerization in a second reactor. Table 6 below provides the reactor conditions and the properties of the polymer produced for Inventive Example 1.







TABLE 6







REACTOR CONDITIONS










Temperature, ° C.
82.0



H2/C2 ratio
0.1416



C6/C2 ratio
0.0131



C2 partial pressure, PSIG
55.0



Calculated Production Rate, lbs/hr
36.4



Bed Weight, lbs
82.4



Static Volts 90 min average
23.0



Static Range 90 average
77.3



Cocatalyst type
Triethylaluminum




(TEAL)



Continuity Additive (CA), ppm in bed
10



Isopentane, mole %
18.5



delta dew point
5.6



Residence Time, hours
2.27







POLYMER PROPERTIES










I21, dg/min
1.120



Density, g/cc
0.9377



Average Particle Size, inch
0.029



Bulk Density, lb/ft3
25.900



Ti ppmw
3.95



Al ppmw
28.92










A representative sample of the bulk polymer was fractionated using a standard geometric sieve set (10/18/35/60/120/200—followed by pan) with openings in the sieve set of 2000/1000/500/250/125/70 microns, respectively. The residual aluminum content in the fractions was determined via X-Ray Fluorescence (XRF) using appropriate standards. The residual aluminum content was essentially constant across all polymer particle sizes, as detailed in Table 7 below, which provides the analysis for two separate samples of Inventive Example 1.











TABLE 7







Average
Sample 2 of
Average


Polymer
Sample 1 of
Al by
Inventive
Al by


Particle Size
Inventive
XRF,
Example 1,
XRF,


(micron)
Example 1, Wt %
Sample 1
Wt %
Sample 2



















Example 1






2000
3.6287
29
30
29.5


1000
36.6802
28
27
27.5


500
28.4707
25
26
25.5


250
18.7506
29
30
29.5


125
8.4994
35
35
35


70
2.2401


less than 70
1.7396










Blended Sample
31
32
31.5









For Inventive Example 2, the polymerization was performed in linked reactors to produce a very broad molecular weight distribution polymer. Table 8 below provides the reactor conditions and the properties of the polymer produced for Inventive Example 2. The first reactor product was fractionated as described above in connection with Inventive Example 1, and the results are given in Table 9.







TABLE 8







REACTOR PROPERTIES










Temperature, ° C.
82.0



H2/C2 ratio
0.1000



C6/C2 ratio
0.0181



C2 partial pressure, PSIG
42.4



Calculated Production Rate, lbs/hr
30.0



Bed Weight, lbs
150.5



Static Volts 90 min average
−63.2



Static Range 90 average
317.3



Cocatalyst type
TEAL



Continuity Additive, ppm in bed
12



Isopentane, mol %
18.1



delta dew point
7.0



Residence Time, hours
5.02







POLYMER PROPERTIES










Al, ppmw
42.39



I21, dg/min
0.937



Density, g/cc
0.9353



Average Particle Size, inch
0.035



Bulk Density, lb/ft3
24.100



Ti, ppmw
3.89
























TABLE 9





Particle









Size
wt % on
Density
Density

I21
Al
Al


(micron)
Screen
(g/cc)*
Delta
ln I21
(dg/min)*
(ppm)**
Variation***






















Inventive
Bulk
0.9351

−0.07
0.937
66.5



Example 2


2000
3.83
0.9352
−0.0001
0.28
1.321
72.5
0.090226


1000
25.28
0.9340
0.0011
0.00
1.000
61
−0.08271


 500
26.92
0.9338
0.0013
0.00
1.002
82
0.233083


 250
22.77
0.9355
−0.0004
−0.13
0.880
65
−0.02256


 125
15.73
0.9368
−0.0017
−0.30
0.738
60.5
−0.09023


 70
3.68
nd****


nd
nd


less than 70
1.79
Nd


nd
nd





*Extruded or Pellets


**Average of two measurements


***(measured average)/average


****“nd” means not detected.






The density and I21 values were all within the repeatability limits of the method or the standard deviation of the mean.
For Inventive Example 3, the polymerization was conducted in a dual reactor system as described in WO2008US87581 and WO2008US87378. Table 10 below provides the reactor conditions for both the first and second reactors for Inventive Example 3. Table 11 lists the properties of the polymer produced in the first reactor. Table 12 lists the properties of the polymer produced in the second reactor. The second reactor polymer product was fractionated as described above in connection with Inventive Example 1, and the results are given in Table 13.








TABLE 10





1ST REACTOR CONDITIONS
2ND REACTOR CONDITIONS


















Temperature, ° C.
82.0
Temperature, ° C.
110.0


H2/C2 ratio
0.1187
H2/C2 ratio
0.601


C6/C2 ratio
0.0065
C6/C2 ratio
0.0004


C2 partial pressure, PSIG
70.7
C2 partial pressure, PSIG
93.3


Calculated Production
33.6
Calculated Production
21.5


Rate, lbs/hr

Rate, lbs/hr


Inlet Dew Point, ° C.
68.6
Split by Ti Analysis
0.688


Bed Weight, lbs
78.5
Energy Balance Rate
21.3




lb/hr


Cocatalyst type
TEAL
Energy Balance Rate
55.1


Continuity Additive, ppm
10.5
Mass Balance Hourly
52.2


in bed

rate


Isopentane mol %
18.1
Bed Weight, lbs
129.5


Residence Time, hours
2.34
Residence Time, hours
2.35
















TABLE 11





FIRST REACTOR POLYMER PROPERTIES


















I21, dg/min
0.648



Density, g/cc
0.9409



Average Particle Size, inch
0.043



Fines, wt %
1.630



Bulk Density, lb/ft3
25.100



Residual Ti, ppmw
2.11



Residual Al, ppmw
23.32

















TABLE 12





SECOND REACTOR POLYMER PROPERTIES


















I21/I2
85.76923



I2, dg/min
0.0793



I21, dg/min
6.8056



I5, dg/min
0.3601



I21/I5
18.9



Density, g/cc
0.9534



Bulk Density, lb/ft3
28.4005



Average Particle Size, inch
0.0436



Fines, wt %
1.6694



Residual Al, ppmw
21.9733



Residual Ti, ppmw
1.4496



Al/Ti ratio
26.91

























TABLE 13





Particle



Absolute






Size

Density
Density
Value

I2,
ln
I5,


(micron)
wt %
(g/cc)
Delta
Difference
ln I2
dg/min
(I5)
dg/min























Inventive
Bulk
0.9538


−2.50
0.082
−1.02
0.36


Example 3


2000
8.77
0.9521
0.0017
0.0017
−2.32
0.099
−0.86
0.42


1000
36.88
0.9537
.0001
.0001
−2.58
0.076
−1.03
0.36


 500
25.51
0.9541
−0.0003
0.0003
−2.33
0.098
−0.87
0.42


 250
19.56
0.9551
−0.0013
0.0013
−2.26
0.104
−0.78
0.46


 125
8.17
0.9541
−0.0003
0.0003
−2.42
0.089
−0.97
0.38














Particle






Size


I21,


(micron)
wt %
ln (I21)
dg/min
Al ppm














Example 3
Whole
1.95
7.01
20.5


2000
8.77
2.05
7.79
26


1000
36.88
1.91
6.74
23


 500
25.51
2.10
8.18
22.5


 250
19.56
2.09
8.12
21.5


 125
8.17
1.95
7.02
21.5


 70
0.50
nd


less than 70
0.61
nd









Samples of the polymer of Inventive Example 3 were converted into pellets in a KOBETM LCM-100 twin screw extruder and then converted into inflation films, as is generally known in the art. More specifically, the inflation film is formed by extruding the polymer resin at a temperature within the range of from 180 to 220° C., for example, and subsequently causing the extruded sheet, by means of a proper form of air, to be simultaneously cooled and inflated to a prescribed size. The film appearance rating was good indicating the substantial absence of gels.
For Inventive Example 4, the polymerization was conducted as described for Inventive Example 1 except that the conditions of the sole reactor were at the values set out in Table 14. The polymer product was fractionated as described above in connection with Inventive Example 1, and the results are given in Table 15.










TABLE 14









Temperature, ° C.
82.00



C2 partial pressure, PSIG
71.8918



C6/C2 ratio
0.0145



H2/C2 ratio
0.1050



Residence Time, hours
~3.5



Isopentane, mol %
16.61



Bulk Density, lb/ft3
22.80



Average Particle Size, inch
0.047






















TABLE 15





Particle Size

Density
Density

I21,


Microns
Wt %
(g/cc)
Delta
In (I21)
dg/min




















Bulk Sample

0.9369

−0.29
0.751


2000
9.330
0.9357
0.0012
−0.02
0.983


1000
50.110
0.9366
0.0003
−0.14
0.867


500
24.250
0.9366
0.0003
−0.10
0.906


250
11.660
0.937
−0.0001
−0.17
0.846


125
4.030
0.9375
−0.0006
−0.33
0.722


70
0.450
nd


nd


less than 70
0.170
nd


nd









As can be seen in Table 15, greater than 95% of the resin particles have the same physical properties.
Comparative Example 1
Catalyst Precursor and Procatalyst Preparation, Polymerization and Polymer
Comparative Example Procatalyst 1 was prepared following the examples of U.S. Pat. No. 6,187,866, except as expressly described. The disclosure of U.S. Pat. No. 6,187,866 is incorporated herein by reference. A feedstock primarily containing anhydrous tetrahydrofuran (THF), dried to less than about 50 ppm water, was heated to approximately 50° C. Granular magnesium metal (100 to about 4000 micron in particle size) was then added to the THF followed by addition of titanium tetrachloride. The mixture was then heated to approximately 70° C. Without being bound by any particular theory, it is currently believed that the Mg metal chemically reduces the titanium tetrachloride to lower valence states, primarily to the +3 valence state. An Mg/Ti molar ratio of slightly higher than 0.5 was used to assure essentially complete reduction of the Ti+4 to lower valence states. Magnesium dichloride was then added to bring the total molar ratio of Magnesium to Titanium in the mixture to between 5.5:1 and 6:1. This mixture was then heated and mixed further for approximately 4 to 6 hours followed by filtration to remove any unreacted magnesium metal and impurities present in the magnesium dichloride that were insoluble in the THF. Finally, fumed silica, CAB-O-SILTM TS-610, was added and mixing was continued until the fumed silica was dispersed, producing a spray drying feedstock. Per 100 liters of THF, 4.8 to 5 moles of Magnesium metal, 9.7 to 10.1 moles of titanium tetrachloride and 49 to 55 moles of magnesium dichloride were used to make the solution. Approximately 6.2 to 7 kilograms of the fumed silica were added to produce the spray drying feedstock. The spray drying feedstock was spray dried using a Niro Atomizer 8-foot diameter closed cycle spray dryer equipped with an FS-15 rotary atomizer using nitrogen as the drying gas. The rotary atomizer was adjusted to give catalyst particles with a D50 of 18 microns. The spray dried catalyst precursor contained approximately 2.5 weight percent Ti, 6.3 weight percent Mg, and 25 to 29 weight percent THF. The spray dried catalyst precursor particles had a D50 of 25 microns and a span [(D90-D10)÷D50] of less than 2 as determined by means of a Leeds and Northrup MICROTRACTM particle size analyzer using a dodecane solvent. The catalyst precursor particles were mixed with mineral oil under a nitrogen atmosphere to form a slurry containing approximately 28 weight percent of the solid catalyst precursor. The catalyst precursor slurry was then fed to the polymerization reactor. Triethyaluminum was used as cocatalyst.
For Comparative Example 1, the polymerization was conducted in a dual reactor system according to example 1 of U.S. Pat. No. 7,714,072, with the exception that the catalyst precursor was not pre-contacted with aluminum alkyl prior to introduction into the reactor. The disclosure of U.S. Pat. No. 7,714,072 is incorporated herein by reference. The resulting granular resin was sieved using the sieve set described in connection with Inventive Example 1 and the key resin melt flow properties were measured. Table 16 lists the conditions of both first and second reactors and the properties of the polymers produced in each reactor.








TABLE 16







FIRST REACTOR CONDITIONS
SECOND REACTOR CONDITIONS













Temperature, ° C.
85  
Temperature, ° C.
110.0


H2/C2 ratio
0.023 to 0.026
H2/C2 ratio
1.55 to 1.65


C6/C2 ratio
 0.03 to 0.035
C6/C2 ratio
0.010


C2 partial pressure, PSI
32 to 38
C2 partial pressure, PSI
75 to 80


Cocatalyst type
TEAL
Split
~0.6


Residence Time, hours
2.3 to 2.4
Residence Time, hours
  2 to 2.2











FIRST REACTOR POLYMER
SECOND REACTOR POLYMER


PROPERTIES
PROPERTIES













I21, dg/min
0.5
I21, dg/min
11 to 12


Density, g/cc
0.930 to 0.932
I2, dg/min
 0.1 to 0.12


Average Particle Size
0.027 to 0.030
Density, g/cc
0.9534


(APS), inch


Fines wt %
4 to 5
Bulk Density lb/ft3
23 to 24


Bulk Density lb/ft3
20 to 21
APS, inch
0.028 to 0.030


Ti ppm
4..5 to 5   
Fines wt %
3.5 to 4  


Al/Ti ratio
35 to 40
Al/Ti
50 to 60




Ti ppm
2.8 to 3.0









A sample of the polymer produced in the second reactor for Comparative Example 1 was examined for polymer particle size distribution as described in connection with Inventive Example 1. The particle size distribution is shown in Table 17. Table 17 further includes flow properties for each of the fractions obtained in the sieving process.












TABLE 17





Avg. Size
% In

I2,
I21,



μm
Band
Cumulative %
dg/min
dg/min
I21/I2




















88
2.73
2.73
0.1540
28.5
185.1


115
5.38
8.11
0.1610
21.4
132.9


162
12.44
20.55
0.1280
15.8
123.4


229
4.64
25.19
0.1380
15.5
112.3


354
33.08
58.27
0.1190
13.7
115.1


595
21.82
80.09
0.0928
11.4
122.8


771
11.15
91.24
0.0556
6.89
123.9


917
4.80
96.04

5.14


1414
3.93
99.97

3.52


3070
0.03
100.00


Bulk


0.1020
11.5
113


Polymer









For Comparative Example 2, the polymerization reaction was carried out as described for Comparative Example 1 except that the reaction conditions were adjusted to increase the overall residence time in each of the reactors. Table 18 lists the conditions for both the first and second reactors for Comparative Example 2.








TABLE 18







FIRST REACTOR CONDITIONS
SECOND REACTOR CONDITIONS













Temperature, ° C.
85
Temperature, ° C.
110.0


H2/C2 ratio
0.023 to 0.026
H2/C2 ratio
 1.6 to 1.65


C6/C2 ratio
 0.03 to 0.032
C6/C2 ratio
0.010


C2 partial
40 to 42
C2 partial
70 to 75


pressure, PSI

pressure, PSI


Cocatalyst type
TEAL
Split
~0.6


Residence Time,
2.6 to 2.8
Residence
2.8 to 3  


hour

Time, hour











FIRST REACTOR POLYMER
SECOND REACTOR POLYMER


PROPERTIES
PROPERTIES













I21, dg/min
0.4 to 0.5
I21, dg/min
11 to 12


Density, g/cc
0.930 to 0.932
Density, g/cc
0.946 to 0.948


APS, inch
0.025 to 0.027
APS, inch
0.026 to 0.028


Bulk Density
20 to 21
Bulk Density lb/ft3
23 to 24


lb/ft3


Fines wt %
4 to 5
Fines wt %
5 to 6


Al/Ti ratio
35 to 40
Al/Ti ratio
50 to 60


Ti ppmw
4.5 to 5  
Ti ppmw
2.8 to 3  




I2, dg/min
0.09 to .1 









A sample of the polymer produced Comparative Example 2 in the second reactor was examined for polymer particle size distribution as described in connection with Inventive Example 1. The particle size distribution for Comparative Example 2 is shown in Table 19. Table 19 further includes flow properties for each of the fractions obtained in the sieving process.












TABLE 19





Avg. Size,
% in
%
I2,
I21,



μm
Band
Cumulative
dg/min
dg/min
I21/I2




















88
2.14
2.14
0.1542
23.9
155.0


115
4.69
6.83
0.1432
14.0
97.8


162
11.54
18.37
0.1096
13.8
125.9


229
4.40
22.77
0.1082
13.1
121.1


354
31.79
54.56
0.0898
10.1
112.5


595
23.52
78.08
0.0564
8.64
153.2


771
12.18
90.26

5.63


917
5.28
95.54

3.86


1414
4.43
99.97


3070
0.03
100.00


Bulk


0.0942
9.49
101


Sample









For Comparative Example 3, the polymerization reaction was as described for Comparative Example 1 except that the reaction conditions were adjusted to lower the overall residence time in each of the two reactors. Table 20 lists the conditions for both the first and second reactors for Comparative Example 3.








TABLE 20







FIRST REACTOR CONDITIONS
SECOND REACTOR CONDITIONS













Temperature, ° C.
85   
Temperature, ° C.
110.0


H2/C2 ratio
0.023 to 0.026
H2/C2 ratio
1.65 to 1.75


C6/C2 ratio
 0.03 to 0.035
C6/C2 ratio
0.002


C2 partial
40 to 44
C2 partial
80 to 85


pressure, PSI

pressure, PSI


Cocatalyst type
TEAL
Split
~0.6


Residence Time,
1.6 to 1.8
Residence Time, hr
  1 to 1.2


hr











FIRST REACTOR POLYMER
SECOND REACTOR POLYMER


PROPERTIES
PROPERTIES













I21, dg/min
0.4 to 0.5
I21, dg/min
11 to 12


Density, g/cc
0.928 to 0.930
Density, g/cc
0.946 to 0.948


APS, inch
0.025 to 0.027
Bulk Density, lb/ft3
23 to 24


Fines wt %
4 to 5
APS, inch
0.026 to 0.028


Bulk Density,
25.100
Fines wt %
5 to 6


lb/ft3


Ti ppmw
3..5 to 4   
Al/Ti ratio
50 to 60


Al/TI ratio
35 to 40
Ti ppmw
2.2 to 2.4




I2, dg/min
0.09 to .1 









A sample of the polymer produced Comparative Example 3 in the second reactor was examined for polymer particle size distribution as described in connection with Inventive Example 1. The particle size distribution for Comparative Example 3 is shown in Table 21. Table 21 further includes flow properties for each of the fractions obtained in the sieving process.












TABLE 21





Avg. Size,
% in
%
I2,
I21,



μm
Band
Cumulative
dg/min
dg/min
I21/I2




















88
2.75
2.75
0.1196
25.8
215.7


115
4.81
7.56
0.1032
21.4
207.4


162
12.28
19.84
0.0972
16.0
164.6


229
4.49
24.33
0.0992
12.1
122.0


354
31.58
55.91
0.1088
12.4
114.0


595
23.31
79.22
0.0676
9.47
140.1


771
11.98
91.20
0.0462
6.26
135.5


917
4.68
95.88

4.85


1414
4.05
99.93

3.9


3070
0.07
100.00


Bulk


0.0948
10.1
107


Sample









As can be seen in Tables 19 and 21, neither of Comparative Examples 2 or 3 provided an improvement in the granular heterogeneity or in the final polymer. For each of the polymers produced in Comparative Examples 2 and 3, polymer samples were converted into pellets using an LCM-100 extruder with a 100 mesh screen pack (i.e. the melt passed through a 100 mesh screen). The pellets were then converted into inflation films and the appearance of the films judged visually based on standards that range from +50 which equates to a substantial absence of any imperfections in the film to −50 which equates to an extremely poor looking film with multiple imperfections including solid gel particles trapped within the film. All of the films had negative film ratings meaning that imperfections, gels and regions of poorly mixed polymer were readily observable to the naked eye. Commercially acceptable films have film ratings of +20 or higher, preferably at least +30.
Test Methods
Density
Resin density was measured by the Archimedes displacement method, ASTM D 792-00, Method B, in isopropanol. Specimens were measured within one hour of molding, after conditioning in the isopropanol bath at 23° C., for 8 minutes, to achieve thermal equilibrium prior to measurement. The specimens were compression molded according to ASTM D-4703-00, Annex A, with a five minutes initial heating period at about 190° C., and a 15° C./min cooling rate per Procedure C. The specimen was cooled to 45° C. in the press, with continued cooling until “cool to the touch.”
Melt Flow Rate by Extrusion Plastomer
Melt flow rate measurements for the ethylene-based polymers were performed according to ASTM D-1238-04, Condition 190° C./2.16 kg, Condition 190° C./5 kg and Condition 190° C./21.6 kg, which are known as I2, I5 and I21, respectively. Melt flow rate is inversely proportional to the molecular weight of the polymer. Thus, the higher the molecular weight, the lower the melt flow rate, although the relationship is not linear. Melt Flow Ratio (MFR) is the ratio of melt flow rate (I21) to melt flow rate (I2), unless otherwise specified.
Residual Metals
Titanium, aluminum and hafnium residuals were measured as ppm by wt using X-ray Diffraction techniques with appropriate standards.
Particle Size and Bulk Density
Particle size was measured using a standard set of mesh sieves—10/18/35/60/120/200/pan with openings of 2000, 1000, 500, 250, 125 and 70 microns respectively and calculated using the mass of resin retained on each sieve. Fines are defined as resin particles on the 200 mesh screen and on the pan.
The Bulk Density measurement was a poured bulk density using a standard 500 cc volumetric cylinder.
The present invention may be embodied in other forms without departing from the spirit and the essential attributes thereof, and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.

## Claims

1. A virgin granular polymer comprising polymer particles wherein at least 90% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean I21 of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1, and further wherein the virgin granular polymer has an I21 less than or equal to 70, and wherein particle size fractions in the range of from 125 to 2000 microns of the said virgin granular polymer have a density within +0.0022 g/cc of each other.

2. The virgin granular polymer of claim 1, wherein the granular polymer is produced in a two stage linked reactor system.

3. The virgin granular polymer of claim 1, wherein the granular polymer is produced in a one stage reactor system.

4. The virgin granular polymer of claim 1, wherein the granular polymer is produced in a fluidized bed reactor system.

5. The virgin granular polymer of claim 1, wherein the granular polymer is produced in a slurry reactor system.

6. The virgin granular polymer of claim 1, wherein the virgin granular polymer has an I21 less than or equal to 30.

7. The reaction product of polymerizing at least one olefin monomer in the presence of: (A) at least one catalyst precursor produced by contacting a Group 4 metal compound with one or more titanium compounds selected from the group of TiCl3 (Al-activated or hydrogen-reduced), and Ti(OR)4 where R is ethyl, isopropyl or n-butyl in the presence of an alcohol solution comprising at least one C2-C4 alcohol and at least one of MgCl2 and magnesium compounds which form MgCl2 in the presence of the alcohol solution to form a catalyst precursor solution, forming said catalyst precursor solution into solid particles and subsequently halogenating the solid particles; and (B) at least one co-catalyst; wherein the reaction product comprises a granular polymer comprised of polymer particles and further wherein at least 90% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean I21 of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1, and wherein at least particle size fractions in the range of from 125 to 2000 microns of the said granular polymer have a density within +0.0022 g/cc of each other.

8. The reaction product of claim 7, wherein at least 95% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1.

9. The reaction product of claim 7, wherein at least 93% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1.

10. The reaction product of polymerizing at least one monomer, in the gas phase, in the presence of: (A) at least one catalyst precursor produced by contacting a Group 4 metal compound with one or more titanium compounds selected from the group of TiCl3 (Al-activated or hydrogen-reduced), and Ti(OR)4 where R is ethyl, isopropyl or n-butyl in the presence of an alcohol solution comprising at least one C2-C4 alcohol and at least one of MgCl2 and magnesium compounds which form MgCl2 in the presence of the alcohol solution to form a catalyst precursor solution, forming said catalyst precursor solution into solid particles and subsequently halogenating the solid particles; and (B) at least one co-catalyst; wherein the reaction product comprises a granular polymer comprised of polymer particles and further wherein at least 90% by weight of the granular polymer particles, have a density that is within two standard deviations of a mean density of the granular polymer, the ratio of the standard deviation of the mean density of the granular polymer to the mean density of the granular polymer is less than 0.002 and the ratio of the standard error of a linear fit to the mean of the density is less than 0.001, and wherein particle size fractions in the range of from 125 to 2000 microns of the said granular polymer have a density within +0.0022 g/cc of each other.

11. The reaction product of claim 10, wherein at least 95% by weight of the granular polymer particles, have a density that is within two standard deviations of a mean density of the granular polymer, the ratio of the standard deviation of the mean density of the granular polymer to the mean density of the granular polymer is less than 0.002 and the ratio of the standard error of a linear fit to the mean of the density is less than 0.001.

12. The reaction product of claim 10, wherein at least 93% by weight of the granular polymer particles, have an I21 that is within two standard deviations of a mean I21 of the granular polymer, the ratio of the standard deviation of I21 to the mean I21 of the granular polymer is less than 0.2 and the ratio of the standard error of a linear fit to the mean of the granular polymer is less than 0.1.