Polymerization catalyst and process

Claim 1

A catalyst which forms on mixing a first catalyst component and a second catalyst component wherein the first catalyst component is formed by the chemical combination of (1) a metal hydrocarbyloxide compound comprising M(OR) 2 where M is a metal selected from Group IIA and Group IIB of the Mendeleev Periodic Table and R is the same or different and is a hydrocarbyl group having from 1 to 20 carbon atoms and (2) a transition metal hydrocarbyloxide compound in which the transition metal is selected from the group consisting of Group IVB and Group VB transition metals of the Mendeleev Periodic Table and wherein the hydrocarbyl group is as defined in (1) and wherein the second catalyst component is a precipitating agent comprising organometallic compounds in which the metal is selected from metals of Groups I to III of the Mendeleev Periodic Table, metal halides and oxygen-containing metal halides of elements selected from Group IIIA, IVA, IVB, VA and VB of the Mendeleev Periodic Table, hydrogen halides, and organic acid halides having the formula ##STR2## wherein R' is an alkyl, aryl, cycloalkyl group or combinations thereof containing from 1 to about 12 carbon atoms, and X is a halogen atom, and further wherein the first and second catalyst components are contacted together at a temperature below about 25° C., and wherein the catalyst comprising the first and second components is contacted with a transition metal halide ion exchange source.

Claim 14

A method for preparing a catalyst comprising mixing together a first catalyst component comprising a metal hydrocarbyloxide compound and a transition metal hydrocarbyloxide compound in a suitable solvent to produce a first catalyst component solution, heating the first catalyst component solution, cooling the first catalyst component solution after heating and optionally filtering the first catalyst component solution to remove any undissolved material from the cooled first catalyst component solution, adding a precipitating agent comprising a second catalyst component to the first cooled catalyst component solution which is at a temperature below about 25° C. under conditions so as to avoid a significant temperature rise in the solution to produce a solid catalyst in the form of a slurry with the solvent, said second catalyst component comprising an organometallic compound in which the metal is selected from metals of Groups I to III of the Mendeleev Periodic Table, metal halide and oxygen-containing metal halides of elements selected from Group IIIA, IVA, IVB, VA and VB of the Mendeleev Periodic Table, hydrogen halides, and organic acid halides having the formula ##STR3## wherein R' is an alkyl, aryl, cycloalkyl group or combinations thereof containing from 1 to about 12 carbon atoms, and X is a halogen atom, washing and drying the solid catalyst and contacting same with said halide ion exchange source by mixing together the washed and dried solid catalyst, the halide ion exchange source, and a liquid hydrocarbon to produce a slurry, and separating the solid catalyst from the liquid hydrocarbon followed by washing and drying the solid catalyst.

Claim 15

A method for preparing a catalyst comprising mixing together a first catalyst component comprising a metal hydrocarbyloxide compound and a transition metal hydrocarbyloxide compound in a suitable solvent to produce a first catalyst component solution, heating the first catalyst component solution, cooling the first catalyst component solution after heating and optionally filtering the first catalyst component solution to remove any undissolved material from the cooled first catalyst component solution, adding a precipitating agent comprising a second catalyst component to the first cooled catalyst component solution which is at a temperature below about 25° C. under conditions so as to avoid a significant temperature rise in the solution to produce a solid catalyst in the form of a slurry with the solvent, said second catalyst component comprising an organometallic compound in which the metal is selected from metals of Groups I to III of the Mendeleev Periodic Table, metal halide and oxygen-containing metal halides of elements selected from Group IIIA, IVA, IVB, VA and VB of the Mendeleev Periodic Table, hydrogen halides, and organic acid halides having the formula ##STR3## wherein R' is an alkyl, aryl, cycloalkyl group or combinations thereof containing from 1 to about 12 carbon atoms, and X is a halogen atom, washing and drying the solid catalyst and contacting same with said halide ion exchange source by mixing together the washed and dried solid catalyst, the halide ion exchange source, and a liquid hydrocarbon to produce a slurry, and separating the solid catalyst from the liquid hydrocarbon followed by washing and drying the solid catalyst.