Polymerization catalyst

Claim 2

A catalyst component for the polymerization of alpha-olefins comprising the solid reaction product obtained by contacting in an inert solvent an inert solid porous particulate support material, (A) at least one organometallic compound of a Group IIA, IIB and IIIA metal, (B) at least one transition metal compound of a Group IVB, VB, VIB, VIIB and VIII metal, and at any stage of the contacting, (C) a sufficient amount of a halogen or interhalogen compound such that after said solid oxide is contacted with said organometallic compound and said transition metal compound halogen or interhalogen compound is available.

Claim 3

The catalyst component of claim 1 wherein the inert solid particulate porous support material is a solid oxide support of a Group IIA, IIIA, IVA and IVB metal or a finely divided polyolefin and is contacted in separate stages with (A) the organometallic compound represented by the formula: Me.sub.x.sup.II Me.sub.y.sup.III R.sub.z X.sub.2x+3y-z wherein Me II is Group IIA or IIB metal or mixture thereof and Me III is a Group IIIA metal or mixtures thereof, R is a hydrocarbyl group having from 1 to about 20 carbon atoms, X is a halogen or alkoxide or mixtures thereof, the ratio of y/x+y is from 0 to 1, z has a value within the range of 1 to 2x+3y, (B) the transition metal compound or mixtures thereof represented by the formula TrX' 4-q (OR') q , TrX' 4-q R" q , VOX' 3 or VO(OR') 3 wherein Tr is a transition metal, R' is a hydrocarbyl group having from 1 to 20 carbon atoms, R" is an aryl group or aralkyl group, having from 1 to 20 carbon atoms and 1,3-cyclopentadienyls, X' is halogen and q is 0 or a number equal to or less than 4, and (C) the halogen or interhalogen is chlorine or bromine.

Claim 4

The catalyst component of claim 2 wherein the organometallic composition is represented by the formula (R 2 Mg) x (R n AlX 3-n ) y wherein n is a number from 1 to 3 and x is greater than zero and the transition metal compound is TiCl 4 .

Claim 5

The catalyst component of claim 1 wherein the contacting with the inert solid particulate porous support material is in the sequential order of, (1) organometallic compound, (2) transition metal compound and (3) halogen or interhalogen compound.

Claim 6

The catalyst component of claim 1 wherein the contacting with the inert solid particulate porous support material is in the sequential order of (1) halogen or interhalogen compound, (2) organometallic compound (3) transition metal compound.

Claim 7

The catalyst component of claim 1 wherein the halogen compound is contacted continuously.

Claim 8

The catalyst component of claim 2 wherein the halogen or inherhalogen compound is contacted with a product recovered from the contacting of the organometallic compound and transition metal compound with the solid oxide support.

Claim 9

The catalyst component of claim 7 wherein the solid oxide support is selected from the group consisting of silica, alumina and silica-alumina.

Claim 10

A catalyst component for the homo or co-polymerization of ethylene comprising the solid reaction product obtained by contacting in an inert solvent (a) silica (b) [(n-C 4 H 9 )(C 2 H 5 )Mg][(C 2 H 5 ) 3 Al] y wherein y is zero or a number of from about 0.01 to about 2, (c) TiCl 4 and (d) Cl 2 .

Claim 11

A catalyst component for the homo or co-polymerization of ethylene comprising the solid reaction product obtained by contacting in an inert solvent (a) silica (b) [(n-C 4 H 9 )(C 2 H 5 )Mg][(C 2 H 5 ) 3 Al] y wherein y is zero or a number of from about 0.01 to about 2, (c) TiCl 4 and (d) Cl 2 .

Claim 12

The catalyst component of claim 9 wherein the reactants are contacted in the sequential order of (a), (b), (c) and (d).

Claim 13

A catalyst component for the polymerization of alpha-olefins comprising the solid reaction product obtained by contacting in an inert solvent an organometallic compound of a Group IIA, IIB or an organometallic complex compound of a IIA/IIIA metal, a transition metal compound of a Group IVB, VB, VIB, VIIB and VIII metal and a halogen or interhalogen compound.

Claim 14

A catalyst component for the polymerization of alpha-olefins comprising the solid reaction product obtained by contacting in an inert solvent an organometallic compound of a Group IIA, IIB or an organometallic complex compound of a IIA/IIIA metal, a transition metal compound of a Group IVB, VB, VIB, VIIB and VIII metal and a halogen or interhalogen compound.

Claim 15

A catalyst system for the polymerization of alpha-olefins comprising the catalyst component of claim 1 and an organoaluminum compound of the formula AlR" n X" 3-n wherein R" is hydrogen, hydrocarbyl or substituted hydrocarbyl group having 1 to 20 carbon atoms, X is a halogen and n is a number from 1 to 3.

Claim 16

A catalyst system for the polymerization of alpha-olefins comprising the catalyst component of claim 2 and an organoaluminum compound of the formula AlR" n X" 3-n wherein R" is hydrogen, hydrocarbyl or substituted hydrocarbyl group having 1 to 20 carbon atoms, x is a halogen and n is a number from 1 to 3.

Claim 17

A catalyst system for the polymerization of alpha-olefins comprising the catalyst component of claim 3 and an organoaluminum compound of the formula AlR" n X" 3-n wherein R" is hydrogen, hydrocarbyl or substituted hydrocarbyl group having 1 to 20 carbon atoms, x is a halogen and n is a number from 1 to 3.

Claim 18

A catalyst system for the polymerization of alpha-olefins comprising the catalyst component of claim 4 and an organoaluminum compound of the formula AlR" n X" 3-n wherein R" is hydrogen, hydrocarbyl or substituted hydrocarbyl group having 1 to 20 carbon atoms, x is a halogen and n is a number from 1 to 3.

Claim 19

A catalyst system for the polymerization of alpha-olefins comprising the catalyst component of claim 5 and an organoaluminum compound of the formula AlR" n X" 3-n wherein R" is hydrogen, hydrocarbyl or substituted hydrocarbyl group having 1 to 20 carbon atoms, x is a halogen and n is a number from 1 to 3.

Claim 20

A catalyst system for the polymerization of alpha-olefins comprising the catalyst component of claim 6 and an organoaluminum compound of the formula AlR" n X" 3-n wherein R" is hydrogen, hydrocarbyl or substituted hydrocarbyl group having 1 to 20 carbon atoms, x is a halogen and n is a number from 1 to 3.

Claim 21

A catalyst system for the polymerization of alpha-olefins comprising the catalyst component of claim 7 and an organoaluminum compound of the formula AlR" n X" 3-n wherein R" is hydrogen, hydrocarbyl or substituted hydrocarbyl group having 1 to 20 carbon atoms, x is a halogen and n is a number from 1 to 3.

Claim 22

A catalyst system for the polymerization of alpha-olefins comprising the catalyst component of claim 8 and an organoaluminum compound of the formula AlR" n X" 3-n wherein R" is hydrogen, hydrocarbyl or substituted hydrocarbyl group having 1 to 20 carbon atoms, x is a halogen and n is a number from 1 to 3.

Claim 23

The catalyst of claim 2 wherein the solid oxide support is silica or alumina.

Claim 24

The catalyst of claim 2 wherein y/x+y is from 0 to about 0.7.

Claim 25

The catalyst of claim 21 wherein y/x+y is from 0 to about 0.1.