Highly active catalyst composition for polymerizing alpha-olefins

Claim 2

A process for preparing a supported catalyst composition for use in alpha-olefin polymerization reactions, said process comprising the steps of: (i) contacting a solid, porous carrier having reactive OH groups with a liquid in the absence of ball milling, said liquid containing at least one organomagnesium composition having the empirical formula R.sub.n MgR'.sub.(2-n) (I) where R is unsubstituted C 1 -C 12 alkyl, R' is Cl, Br or I, and n is a rational number from about 0.5 to 2, the number of moles of said organomagnesium composition being in excess of the number of moles of said OH groups on said carrier, whereby said organomagnesium composition is reacted with said OH groups on said carrier; (ii) evaporating said liquid from step (i) to precipitate magnesium onto said carrier, said precipitated magnesium being selected from the group consisting of magnesium dihalide, unreacted organomagnesium and mixtures thereof, whereby a supported magnesium composition in the form of a dry, free-flowing powder is formed; and (iii) reacting said powder of step (ii) with at least one tetravalent titanium compound in a liquid medium, the number of moles of said tetravalent titanium compound being in excess of the number of OH groups on said carrier prior to reaction with said organomagnesium composition in step (i), said tetravalent titanium compound being soluble in said liquid medium, and said supported magnesium composition being essentially insoluble in said liquid medium, whereby a reacted form of titanium which is insoluble in said liquid medium becomes supported on said carrier.

Claim 3

A process according to claim 1, wherein n is 1.

Claim 4

A process according to claim 2, wherein said contacting step (i) comprises: (a) slurrying said carrier in a non-Lewis base liquid; and (b) adding said organomagnesium composition to said slurry of step (a) in the form of an ether solution of said organomagnesium composition.

Claim 5

A process according to claim 3, wherein said solid, porous carrier is essentially composed of silica, alumina or combinations thereof.

Claim 6

A process according to claim 4, wherein said tetravalent titanium compound is TiCl 4 .

Claim 7

A process for preparing a supported catalyst composition for use in alpha-olefin polymerization reactions, said process comprising the steps of: (i) contacting silica having from about 0.3 to about 0.7 milimoles/g of OH groups with a liquid in the absence of ball milling, said liquid containing at least one organomagnesium composition having the empirical formula RMgR' (II) where R represents C 1 -C 12 hydrocarbyl group and R' represents halogen, at least a portion of said organomagnesium composition being soluble in said liquid medium, the ratio of the number of moles of said organomagnesium composition to the number of moles of OH groups on said silica being from about 1.1 to about 2.5, whereby said organomagnesium composition is reacted with said OH groups on said silica, (ii) evaporating said liquid from step (i) to precipitate magnesium onto said silica, said precipitated magnesium being selected from the group consisting of magnesium dihalide, unreacted organomagnesium and mixtures thereof, whereby a supported magnesium composition in the form of a dry, free-flowing powder is formed; and (iii) reacting said powder of step (ii) with at least one tetravalent titanium compound in a liquid medium, the number of moles of said tetravalent titanium compound being in excess of the number of moles of magnesium supported on said silica, said tetravalent titanium compound being soluble in said liquid medium, and said supported magnesium composition, being essentially insoluble in said liquid medium, whereby a reacted form of titanium which is insoluble in said liquid medium becomes supported on said silica.

Claim 8

A process for preparing a supported catalyst composition for use in alpha-olefin polymerization reactions, said process comprising the steps of: (i) contacting silica having from about 0.3 to about 0.7 milimoles/g of OH groups with a liquid in the absence of ball milling, said liquid containing at least one organomagnesium composition having the empirical formula RMgR' (II) where R represents C 1 -C 12 hydrocarbyl group and R' represents halogen, at least a portion of said organomagnesium composition being soluble in said liquid medium, the ratio of the number of moles of said organomagnesium composition to the number of moles of OH groups on said silica being from about 1.1 to about 2.5, whereby said organomagnesium composition is reacted with said OH groups on said silica, (ii) evaporating said liquid from step (i) to precipitate magnesium onto said silica, said precipitated magnesium being selected from the group consisting of magnesium dihalide, unreacted organomagnesium and mixtures thereof, whereby a supported magnesium composition in the form of a dry, free-flowing powder is formed; and (iii) reacting said powder of step (ii) with at least one tetravalent titanium compound in a liquid medium, the number of moles of said tetravalent titanium compound being in excess of the number of moles of magnesium supported on said silica, said tetravalent titanium compound being soluble in said liquid medium, and said supported magnesium composition, being essentially insoluble in said liquid medium, whereby a reacted form of titanium which is insoluble in said liquid medium becomes supported on said silica.

Claim 9

A process according to claim 6, wherein chemically and physically bound water has been removed from said silica in step (i) by heating at a temperature from about 750° C. to about 850° C. for at least four hours, formula (II) is C 2 H 5 MgCl, said tetravalent titanium compound is TiC1 4 and said liquid medium in step (iii) contains from about 3 to about 6 moles of TiCl 4 per mole of magnesium supported on said silica.

Claim 10

A process for preparing a supported catalyst composition for use in alpha-olefin polymerization reactions, said process comprising the steps of: (i) heating a solid, porous carrier essentially composed of silica having reactive OH groups at a temperature of at least 500° C. for at least 4 hours; (ii) contacting said carrier of step (i) with a liquid in the absence of ball milling, said liquid containing an organomagnesium composition having the empirical formula C.sub.2 H.sub.5 MgCl the number of moles of said organomagnesium composition being present in said liquid in excess of the number of moles of said OH groups, whereby said organomagnesium composition is reacted with said OH groups on said carrier; (iii) evaporating said liquid from step (ii) to precipitate magnesium onto said carrier, said precipitated magnesium being selected from the group consisting of magnesium dichloride, unreacted organomagnesium and mixtures thereof, whereby a supported magnesium composition in the form of a dry free-flowing powder is formed, wherein neither said carrier nor said magnesium has been contacted with either an organoaluminum compound or an aluminum halide compound; and (iv) reacting said powder of step (iii) with TiCl 4 in a liquid medium, the number of moles of said TiCl 4 being in excess of the number of OH groups on said carrier prior to reaction with said organomagnesium composition in step (ii), said TiCl 4 being soluble in said liquid medium, and said supported magnesium composition being essentially insoluble in said liquid medium, whereby a reacted form of titanium which is insoluble in said liquid medium becomes supported on said carrier.

Claim 11

A process for preparing a supported catalyst composition for use in alpha-olefin polymerization reactions, said process comprising the steps of: (i) heating a solid, porous carrier essentially composed of silica having reactive OH groups at a temperature of at least 500° C. for at least 4 hours; (ii) contacting said carrier of step (i) with a liquid in the absence of ball milling, said liquid containing an organomagnesium composition having the empirical formula C.sub.2 H.sub.5 MgCl the number of moles of said organomagnesium composition being present in said liquid in excess of the number of moles of said OH groups, whereby said organomagnesium composition is reacted with said OH groups on said carrier; (iii) evaporating said liquid from step (ii) to precipitate magnesium onto said carrier, said precipitated magnesium being selected from the group consisting of magnesium dichloride, unreacted organomagnesium and mixtures thereof, whereby a supported magnesium composition in the form of a dry free-flowing powder is formed, wherein neither said carrier nor said magnesium has been contacted with either an organoaluminum compound or an aluminum halide compound; and (iv) reacting said powder of step (iii) with TiCl 4 in a liquid medium, the number of moles of said TiCl 4 being in excess of the number of OH groups on said carrier prior to reaction with said organomagnesium composition in step (ii), said TiCl 4 being soluble in said liquid medium, and said supported magnesium composition being essentially insoluble in said liquid medium, whereby a reacted form of titanium which is insoluble in said liquid medium becomes supported on said carrier.

Claim 12

A process according to claim 8, wherein said contacting step (ii) comprises: (a) slurrying said carrier in a non-Lewis base liquid; and (b) adding said organomagnesium composition to said slurry of step (a) in the form of an ether solution of said organomagnesium composition.

Claim 13

A process according to claim 7, wherein, in step (i), the ratio of the number of moles of said organomagnesium composition to the number of moles of OH groups on said silica is from about 1.5 to about 2.5.

Claim 14

A process according to claim 10, wherein, in step (i), the ratio of the number of moles of said organomagnesium composition to the number of moles of OH groups on said silica is from about 2.0 to about 2.5.

Claim 15

A supported catalyst composition for use in alpha-olefin polymerization reactions, prepared by a process comprising the steps of: (i) contacting a solid, porous carrier having reactive Oh groups with a liquid in the absence of ball milling, said liquid containing at least one organomagnesium composition having the empirical formula R.sub.n MgR'.sub.(2-n) (I) where R is unsubstituted C 1 -C 12 alkyl, R' is Cl, Br or I, and n is a rational number from about 0.5 to 2, the number of moles of said organomagnesium composition being in excess of the number of moles of said OH groups on said carrier, whereby said organomagnesium composition is reacted with said OH groups on said carrier; (ii) evaporating said liquid from step (i) to precipitate magnesium onto said carrier, said precipitated magnesium being selected from the group consisting of magnesium dihalide, unreacted organomagnesium and mixtures thereof, whereby a supported magnesium composition in the form of a dry, free-flowing powder is formed; and (iii) reacting said powder of step (ii) with at least one tetravalent titanium compound in a liquid medium, the number of moles of said tetravalent titanium compound being in excess of the number of OH groups on said carrier prior to reaction with said organomagnesium composition in step (i), said tetravalent titanium compound being soluble in said liquid medium, and said supported magnesium composition being essentially insoluble in said liquid medium, whereby a reacted form of titanium which is insoluble in said liquid medium becomes supported on said carrier.

Claim 16

A supported catalyst composition for use in alpha-olefin polymerization reactions, prepared by a process comprising the steps of: (i) contacting a solid, porous carrier having reactive Oh groups with a liquid in the absence of ball milling, said liquid containing at least one organomagnesium composition having the empirical formula R.sub.n MgR'.sub.(2-n) (I) where R is unsubstituted C 1 -C 12 alkyl, R' is Cl, Br or I, and n is a rational number from about 0.5 to 2, the number of moles of said organomagnesium composition being in excess of the number of moles of said OH groups on said carrier, whereby said organomagnesium composition is reacted with said OH groups on said carrier; (ii) evaporating said liquid from step (i) to precipitate magnesium onto said carrier, said precipitated magnesium being selected from the group consisting of magnesium dihalide, unreacted organomagnesium and mixtures thereof, whereby a supported magnesium composition in the form of a dry, free-flowing powder is formed; and (iii) reacting said powder of step (ii) with at least one tetravalent titanium compound in a liquid medium, the number of moles of said tetravalent titanium compound being in excess of the number of OH groups on said carrier prior to reaction with said organomagnesium composition in step (i), said tetravalent titanium compound being soluble in said liquid medium, and said supported magnesium composition being essentially insoluble in said liquid medium, whereby a reacted form of titanium which is insoluble in said liquid medium becomes supported on said carrier.

Claim 17

A supported catalyst composition of claim 12, wherein, in step (i), the ratio of the number of moles of said organomagnesium composition to the number of moles of OH groups on said silica is from about 1.1 to about 2.5.

Claim 18

A supported catalyst composition of claim 13 wherein, in step (i), the ratio of the number of moles of said organomagnesium composition to the number of moles of OH groups on said silica is from about 1.5 to about 2.5.

Claim 19

A supported catalyst composition of claim 14 wherein, in step (i), the ratio of the number of moles of said organomagnesium composition to the number of moles of OH groups on said silica is from about 2.0 to about 2.5.

Claim 20

A supported catalyst composition of claim 15 wherein n is 1.