Catalyst component

Claim 2

A catalyst component which is the product of reacting a particulate support material which has a reactive surface comprising a plurality of sites on the surface of the support which are capable of abstracting a magnesium hydrocarbyl from a solution thereof with (a) at least one organomagnesium compound in which magnesium is directly bonded through a carbon atom to a first hydrocarbyl group and is bonded to a halogen, or oxyhydrocarbyl or a second hydrocarbyl group, which hydrocarbyl group(s) is (are) alkyl, aryl, cycloalkyl, aralkyl, alkadienyl or alkenyl, (b) at least one aluminum compound of the general formula: R n AlY 3-n wherein R, each of which may be the same or different, represents a hydrocarbyl group which is an alkyl, aryl, cycloalkyl, aralkyl, or alkadienyl group, n is 0, 1, 2, 3 or a fraction less than 3 and Y is a singly charged ligand which is hydride, fluoride, chloride, bromide, iodide or oxyhydrocarbyl, (c) at least one transition metal compound of Groups IVA, VA or VIA of the Periodic Table which is known to be useful in forming Ziegler-Natta catalysts, (d) at least one pacifying agent which is capable of breaking metal-carbon or metal-hydrogen bonds in the catalyst component but does not have a deleterious effect on the catalyst component and which is used in sufficient quantity to break substantially all the metal-hydrocarbyl or metal-hydride bonds in the catalyst component, and optionally one or more compounds selected from the group consisting of an organometallic compound of the general formula: R m 1 MX p wherein M is a metal of Groups IA, IIA, IIB, IIIB, IVA, VA OR VIA of the Periodic Table, R 1 is a hydrocarbyl or a substituted hydrocarbyl group, X is a halogen, m is an integer up to the highest valency of the metal M and p is 0 or an integer up to 2 less than the valency of the metal M, except when M is a metal from Group VIA, p is always 0, and when M is a metal from Groups IVA, VA or VIA m has a value from 2 to the highest valency of the metal and p has a value from 0 to a value of 2 less than the valency of the metal M, a halogenating agent and a Lewis Base compound, with the proviso (i) that the particulate support material is treated with the at least one organomagnesium compound, the at least one aluminum compound of general formula R n AlY 3-n , the at least one transition metal compound of Groups IVA, VA or VIA, and the one or more compounds selected from the aforesaid group, where one or more is used, prior to being treated with the at least one pacifying agent, except that where (a) the pacifying agent is a hydrogen halide and (b) the particulate support material is treated with the aluminum compound of general formula R n AlY 3-n and the at least one organomagnesium compound separately, the pacifying agent may be added to the support after the support has been treated with the at least one organomagnesium compound and the aluminum compound of general formula R n AlY 3-n and before the support is treated with the at least one transition metal compound of Groups IVA, VA or VIA and (ii) that where the support is treated with an organometallic compound R m 1 MX p it is treated with a halogenating agent and/or a Lewis base compound, in which catalyst component the molar ratio of the aluminum compound of general formula R n AlY 3-n to the organomagnesium compound is between 0.5 and 100 and the molar ratio of the aforesaid aluminum compound to the transition metal compound is between 1.0 and 2000.

Claim 3

A catalyst component as claimed in claim 1 wherein the reactive surface comprises OH groups attached to the surface of a substantially inert particulate support material.

Claim 4

A catalyst component as claimed in claim 2 wherein the particulate support material is silica and/or alumina.

Claim 5

A catalyst component as claimed in claim 1 wherein the at least one organomagnesium compound has two hydrocarbyl groups directly bonded to magnesium.

Claim 6

A catalyst component as claimed in claim 4 wherein the hydrocarbyl groups are alkyl groups having 1 to 10 carbon atoms.

Claim 7

A catalyst component as claimed in claim 5 wherein at least one of the alkyl groups is a butyl group.

Claim 8

A catalyst component as claimed in claim 1 wherein the transition metal in the at least one transition metal compound of Groups IVA, VA or VIA is titanium, zirconium, vanadium, molybdenum or chromium.

Claim 9

A catalyst component as claimed in claim 7 wherein the said compound is a halide, halo-oxide, alkoxide, haloalkoxide or acetyl acetonate.

Claim 10

A catalyst component as claimed in claim 1 wherein the at least one pacifying agent is carbon dioxide, carbon monoxide, oxygen, or a protic agent which is a hydrogen halide, carboxylic acid, alcohol, water, amine or acetylacetone.

Claim 11

A catalyst component as claimed in claim 9 wherein the protic agent is an aliphatic alcohol having from 1 to about 6 carbon atoms or an anhydrous hydrogen halide.

Claim 12

A catalyst component as claimed in claim 1 wherein the particulate support material is treated with the aluminium compound of general formula R n AlY 3-n prior to being treated with the at least one organomagnesium compound.

Claim 13

A catalyst component as claimed in claim 1 wherein the particulate support material is treated with the at least one transition metal compound of Groups IVA, VA or VIA of the Periodic Table prior to being treated with a pacifying agent which is a hydrogen halide.

Claim 14

A catalyst component as claimed in claim 1 wherein R is an alkyl group having 1 to 4 carbon atoms.

Claim 15

A catalyst component as claimed in claim 1 wherein Y is a halide.

Claim 16

A catalyst component as claimed in claim 1 wherein the at least one aluminium compound is selected from the group consisting of aluminium chloride, aluminium bromide, monoethyl aluminium dichloride, ethyl aluminium sesquichloride and diethyl aluminium chloride.

Claim 17

A catalyst component as claimed in claim 1 wherein M represents a metal from Groups IA, IIA, IIB or IIIB of the Periodic Table, p is O and m is the highest valency of the metal.

Claim 18

A catalyst component as claimed in claim 1 wherein M represents a transition metal of Groups IVA, VA or VIA of the Periodic Table.

Claim 19

A catalyst component as claimed in claim 17 wherein in the organometallic compound R m 1 MX p , at least one of the hydrocarbyl groups R 1 is π-allyl or π-methallyl.

Claim 20

A catalyst component as claimed in claim 18 wherein the organometallic compound is selected from the group consisting of tetrakis (π-allyl)zirconium and hafnium, tris (π-allyl)chromium, tetrakis(π-methallyl)zirconium and hafnium, tris(π-methallyl)chromium and zirconium tris (π-allyl)bromide.

Claim 21

A catalyst component as claimed in claim 17 wherein in the organometallic compound R m 1 MX p , at least one of the hydrocarbyl or substituted hydrocarbyl groups R 1 has the formula --CH 2 Z and is sigma-bonded to the transition metal M through the carbon atom where Z is a mono or polyaromatic group, cycloalkenyl group or the group --A(R 2 ) 3 where A represents carbon, silicon, germanium, tin or lead and R 2 represents a hydrocarbyl or substituted hydrocarbyl group or hydrogen.

Claim 22

A catalyst component as claimed in claim 20 wherein --CH 2 Z is selected from the group consisting of benzyl, 1-methylene-1-naphthyl, p-methylbenzyl, trimethylsilylmethane, neopentyl and neophyl.

Claim 23

A catalyst component as claimed in claim 21 wherein the at least one organometallic compound R m 1 MX p is selected from the group consisting of zirconium and titanium tetrabenzyl, tris(benzyl)zirconium chloride, zirconium tetrakis (p-methylbenzyl), titanium and zirconium (1-methylene-1-naphthyl), zirconium tetrakis(trimethylsilylmethylene), zirconium tetrakis(neopentyl) and zirconium tetrakis (neophyl).

Claim 24

A catalyst component as claimed in claim 1 wherein the halogen containing compound is a halogenating agent.

Claim 25

A catalyst component as claimed in claim 23 wherein the halogenating agent is selected from the group consisting of hydrogen halide, phosphorus pentachloride, thionyl chloride, sulphuryl chloride, phosgene nitrosyl chloride, halides of mineral acids, chlorine, bromine, chlorinated polysiloxanes, hydrocarbyl aluminium halides, aluminium chloride, boron halides, ammonium hexafluorosilicate, silicon halides R 3 SiX 1 .sub.(4-a) where R 3 is hydrogen or a hydrocarbyl group, X 1 is a halide, and a is 0 or an integer from 1 to 3, R 4 COX 1 and R 5 X b 1 where R 4 and R 5 are hydrocarbyl groups, X 1 has the meaning hereinbefore ascribed to it and b is an integer from 1 to 10.

Claim 26

A catalyst component as claimed in claim 1 wherein the Lewis Base compound is an ester of formula R 6 COOR 7 wherein R 6 is a hydrocarbyl group which may be substituted with one or more halogen atoms and/or hydrocarbyloxy groups and R 7 is a hydrocarbyl group which may be substituted with one or more halogen atoms.

Claim 27

A catalyst component as claimed in claim 25 wherein R 6 is an aryl group and R 7 is an alkyl group.

Claim 28

An olefinic polymerisation catalyst comprising a catalyst component as claimed in claim 1 activated with a suitable activator which is an organometallic compound of a metal of Groups I to IV of the Periodic Table which is known to be useful as an activator for Ziegler-Natta catalysts.

Claim 29

An olefin polymerisation catalyst as claimed in claim 27 wherein the said metal is from Groups IA, IIA, IIB, IIIB or IVB of the Periodic Table.

Claim 30

A catalyst as claimed in claim 28 wherein the said metal is aluminium.

Claim 31

A process for the preparation of a catalyst component as claimed in claim 1 comprising the steps of reacting the particulate support material which has a reactive surface comprising a plurality of sites on the surface of the support which are capable of abstracting a magnesium hydrocarbyl from a solution thereof with (a) at least one organomagnesium compound in which magnesium is directly bonded through a carbon atom to a first hydrocarbyl group and is bonded to a halogen, or oxyhydrocarbyl or a second hydrocarbyl group, which hydrocarbyl group(s) is (are) alkyl, aryl, cycloalkyl, aralkyl, alkadienyl or alkenyl, (b) at least one aluminum compound of the general formula: R n AlY 3-n wherein R, each of which may be the same or different, represents a hydrocarbyl group which is an alkyl, aryl, cycloalkyl, aralkyl, or alkadienyl group, n is 0, 1, 2, 3 or a fraction less than 3 and Y is a singly charged ligand which is hydride, fluoride, chloride, bromide, iodide or oxyhydrocarbyl, (c) at least one transition metal compound of Groups IVA, VA or VIA of the Periodic Table which is known to be useful in forming Ziegler-Natta catalysts, (d) at least one pacifying agent which is capable of breaking metal-carbon or metal-hydrogen bonds in the catalyst component but does not have a deleterious effect on the catalyst component and which is used in sufficient quantity to break substantially all the metal-hydrocarbyl or metal-hydride bonds in the catalyst component, and optionally one or more compounds selected from the group consisting of an organometallic compound of the general formula: R m 1 MX p wherein M is a metal of Groups IA, IIA, IIB, IIIB, IVA, VA or VIA of the Periodic Table, R 1 is a hydrocarbyl or a substituted hydrocarbyl group, X is a halogen, m is an integer up to the highest valency of the metal M and p is 0 or an integer up to 2 less than the valency of the metal M, except when M is a metal from Group VIA p is always 0, and when M is a metal from Groups IVA, VA or VIA m has a value from 2 to the highest valency of the metal and p has a value from 0 to a value of 2 less than the valency of the metal M, a halogenating agent and a Lewis Base compound, with the proviso that the particulate support material is treated with the at least one organomagnesium compound, the at least one aluminum compound of general formula R n AlY 3-n , the at least one transition metal compound of Groups IVA, VA or VIA, and the one or more compounds selected from the aforesaid group, where one or more is used, prior to being treated with the at least one pacifying agent, except that where (a) the pacifying agent is a hydrogen halide and (b) the particulate support material is treated with the aluminum compound of general formula R n AlY 3-n and the at least one organomagnesium compound separately, the pacifying agent may be added to the support after the support has been treated with the at least one organomagnesium compound and the aluminum compound of general formula R n AlY 3-n and before the support is treated with the at least one transition metal compound of Groups IVA, VA or VIA and (ii) that where the support is treated with an organometallic compound R m 1 MX p it is treated with a halogenating agent and/or a Lewis base compound, in which catalyst component the molar ratio of the aluminum compound of general formula R n AlY 3-n to the organomagnesium compound is between 0.5 and 100 and the molar ratio of the aforesaid aluminum compound to the transition metal compound is between 1.0 and 200.