Polymerization catalyst and method

Claim 1

A dry, granular and solid olefin polymerization and copolymerization catalyst active in a particle form process in the presence of an organic cocatalyst prepared by reacting, in the presence of a solvent, reactive materials comprising dry particles or an inorganic oxide having active surface hydroxyl or oxide groups and chosen from the group consisting of silica, alumina and silica-alumina, said particles having been preactivated by heating at between about 200° C. and 900° C., and an alcohol containing only carbon, hydrogen and oxygen atoms and no aromatic ring bonded directly to the alcohol hydroxyl grup and an organomagnesium compound comprising a magnesium alkyl or a complex of the general formula (MgR 2 ) m (AlR 3 ') n where R and R' are the same or different alkyl groups of 2-10 carbon atoms each and m/n is between about 0.5 and 10, inclusive, to form a reaction mixture of said solvent and a hydrocarbon insoluble first reaction product, the molar ratio of said alcohol to said organomagnesium compound being 0.1-10 mixing said reaction mixture with a halide, oxyhalide or alkoxyhalide of a metal chosen from the group consisting of titanium, vanadium and zirconium to form a second reaction product, and removing the solvent from said second reaction product to form said dry, granular and solid catalyst.

Claim 20

The method of preparing a dry, granular and solid olefin polymerization and copolymerization catalyst active in a particle form process in the presence of an alkyl aluminum cocatalyst comprising the consecutive steps of: (a) preactivating and drying particles of an inorganic oxide having active surface hydroxyl or oxide groups chosen from the group consisting of silica, alumina and silica-alumina by heating said particles at between about 200° C. and 900° C.; (b) reacting said dry particles in the presence of a hydrocarbon solvent with an alcohol containing only carbon, hydrogen and oxygen atoms and no aromtaic ring bonded directly to the alcohol hydroxyl group and an organomagnesium compound comprising a magnesium alkyl compound, or a complex of the general formula (MgR 2 ) m (AlR 3 ') n wherein R and R' are the same or different alkyl groups of 2 to 10 carbon atoms and m/n is between about 0.5 and 10, inclusive, to form a reaction mixture of said solvent and a first reaction product insoluble in said solvent, the molar ratio of said alcohol to said organomagnesium compound being 0.1-10; (c) reacting said first reaction product in said reaction mixture with a halogen-containing transition metal compound to form a second reaction product, said transition metal compound being selected from the group consisting of Tr(OR") a X 4-a and TrOX 3 , wherein Tr is a transition metal selected from the group consisting of titanium, vanadium and zirconium, R" is an alkyl group of less than about 20 carbon atoms, X is a halogen atom, and a is zero or an integer less than 4; and (d) removing said solvent from said second reaction product to form said dry, granular and solid catalyst.

Claim 21

The method of preparing a dry, granular and solid olefin polymerization and copolymerization catalyst active in a particle form process in the presence of an alkyl aluminum cocatalyst comprising the consecutive steps of: (a) preactivating and drying particles of an inorganic oxide having active surface hydroxyl or oxide groups chosen from the group consisting of silica, alumina and silica-alumina by heating said particles at between about 200° C. and 900° C.; (b) reacting said dry particles in the presence of a hydrocarbon solvent with an alcohol containing only carbon, hydrogen and oxygen atoms and no aromtaic ring bonded directly to the alcohol hydroxyl group and an organomagnesium compound comprising a magnesium alkyl compound, or a complex of the general formula (MgR 2 ) m (AlR 3 ') n wherein R and R' are the same or different alkyl groups of 2 to 10 carbon atoms and m/n is between about 0.5 and 10, inclusive, to form a reaction mixture of said solvent and a first reaction product insoluble in said solvent, the molar ratio of said alcohol to said organomagnesium compound being 0.1-10; (c) reacting said first reaction product in said reaction mixture with a halogen-containing transition metal compound to form a second reaction product, said transition metal compound being selected from the group consisting of Tr(OR") a X 4-a and TrOX 3 , wherein Tr is a transition metal selected from the group consisting of titanium, vanadium and zirconium, R" is an alkyl group of less than about 20 carbon atoms, X is a halogen atom, and a is zero or an integer less than 4; and (d) removing said solvent from said second reaction product to form said dry, granular and solid catalyst.