Process for the preparation of a catalyst and catalyst used in olefin polymerization

Claim 1

In a process for the preparation of a catalyst by reacting the reaction product of silicon dioxide, aluminum oxide, or a mixture thereof, and (a) a halogen-containing magnesium-organic compound and (b) a halogen compound of a transition metal, with an aluminum-organic compound, the improvement which comprises (1) reacting silicon dioxide, aluminum oxide, or a mixture thereof, having a content of hydroxyl groups of from 0.5 to 50 mmols/g, in the presence of a diluent, with a magnesium-organic compound of the formula RMgX, wherein R is hydrocarbon of from 1 to 20 carbon atoms and X is chlorine, bromine or iodine, in an amount of from 0.1 to 0.95 mol of said magnesium-organic compound per mol of hydroxyl groups of the silicon dioxide, aluminum oxide or mixture thereof; (2) reacting the solid reaction product of step (1) in suspension with a halogen-containing titanium compound of the formula TiX n (OR 1 ) 4-n , wherein n is an integer of from 1 to 4, X is chlorine or bromine and R 1 is hydrocarbon of from 1 to 12 carbon atoms, in an amount of from 0.01 to 1 mol of said titanium compound per mol of hydroxyl groups of the silicon dioxide, aluminum oxide or mixture thereof, and in an amount such that the atomic ratio of magnesium to titanium in the reaction product is in the range of from 0.1 to 10; and (3) reacting the product of step (2) with a sufficient amount of an aluminum-organic compound which is a compound of the formula AIR 3 6 or AIR 2 6 H, R 6 being hydrocarbon of from 1 to 16 carbon atoms, a compound of the formula R 2 5 AlCl or R 3 5 Al 2 Cl 3 , R 5 being hydrocarbon of from 1 to 16 carbon atoms, or a product of the reaction of an aluminum trialkyl or an aluminum dialkyl hydride, wherein said alkyl is of from 1 to 16 carbon atoms, with a diene of from 4 to 20 carbon atoms to produce a catalyst which is active in polymerizing a 1-olefin.