Spray dried catalyst compositions, methods for preparation and use in olefin polymerization processes

1. A method for producing a supported catalyst composition for olefin polymerization comprising the steps of:

a) forming a suspension comprising one or more porous particulate supports, one or more activator compounds and one or more catalyst compounds in one or more liquid diluents, wherein step a) is performed in a time of 5 hours or less; and

b) spray drying the suspension to form a supported catalyst composition;

wherein step b) is performed at a rate sufficient to produce at least 200 kg of supported catalyst composition in a time of 5 hours or less.

2. A method according to claim 1 , wherein supported catalyst composition has a residual liquid content after spray drying of 10% by weight or less.

3. A method according to claim 1 , wherein step b) is performed at a rate sufficient to produce at least 500 kg of supported catalyst composition in a time of 10 hours or less.

4. A method according to claim 1 , wherein the suspension has a weight percent of solids in the liquid diluent between about 5% by weight and about 60% by weight.

5. A method according to claim 1 , wherein the suspension is spray dried at a rate between about 100 kg/hr and 1000 kg/hr.

6. A method according to claim 1 , wherein the porous particulate support comprises (i) a particulate Group 2, 3, 4, 5, 13 and 14 oxide or chloride or (ii) a particulate silica.

7. A method according to claim 1 , wherein the porous particulate support has an average particle size in the range of from about 0.1 to about 500 μm.

8. A method according to claim 1 , wherein the one or more activator compounds comprises an organometallic compound.

9. A method according to claim 1 , wherein the one or more activator compounds comprises an alumoxane or a neutral or ionic stoichiometric activator.

10. A method according to claim 1 , wherein the one or more activator compounds comprises a methylalumoxane or a modified methylalumoxane.

11. A method according to claim 1 , wherein the liquid diluent comprises an aliphatic or aromatic hydrocarbon.

12. A method according to claim 1 , wherein the liquid diluent comprises toluene.

13. A method according to claim 1 , wherein the one or more catalyst compounds comprises a titanium, a zirconium or a hafnium atom.

14. A method according to claim 1 , wherein the catalyst compound comprises:

(pentamethylcyclopentadienyl)(propylcyclopentadienyl)MX 2 ,

(tetramethylcyclopentadienyl)(propylcyclopentadienyl)MX 2 ,

(tetramethylcyclopentadienyl)(butylcyclopentadienyl)MX 2 ,

Me 2 Si(indenyl) 2 MX 2 ,

Me 2 Si(tetrahydroindenyl) 2 MX 2 ,

(n-propyl cyclopentadienyl) 2 MX 2 ,

(n-butyl cyclopentadienyl) 2 MX 2 ,

(1-methyl, 3-butyl cyclopentadienyl) 2 MX 2 ,

HN(CH 2 CH 2 N(2,4,6-Me 3 phenyl)) 2 MX 2 ,

HN(CH 2 CH 2 N(2,3,4,5,6-Mesphenyl)) 2 MX 2 ,

(propyl cyclopentadienyl)(tetramethylcyclopentadienyl)MX 2 ,

(butyl cyclopentadienyl) 2 MX 2 ,

(propyl cyclopentadienyl) 2 MX 2 , and mixtures thereof,

wherein M is Zr or Hf, and X is selected from F, Cl, Br, I, Me, benzyl, CH 2 SiMe 3 , and C 1 to C 5 alkyls or alkenyls.

15. A method according to claim 1 wherein a suspension in toluene liquid diluent of particulate silica, methylalumoxane, and one or more catalyst compounds is spray dried at a rate sufficient to produce at least 200 kg of supported catalyst composition in a time of 5 hours or less and having a toluene content of 7% by weight or less.

16. A method according to claim 1 wherein a suspension in toluene liquid diluent of particulate silica, methylalumoxane, and one or more catalyst compounds is spray dried at a rate sufficient to produce at least 500 kg of supported catalyst composition in a time of 5 hours or less and having a toluene content of 7% by weight or less.

17. A method according to claim 1 , spray drying the suspension to form the supported catalyst composition includes proving the suspension a residence time of 5 seconds to 60 seconds in a drying chamber.