Polymerization catalyst, production and use

Claim 2

A vanadium-containing catalyst component obtained by treating an inert solid support material in an inert solvent with (A) a dihydrocarbyl magnesium compound or a complex or mixture of an organic dihydrocarbyl magnesium compound and an aluminum compound, (B) optionally an oxygen-containing compound which is an alcohol, ketone or aldehyde, (C) a Group IIIa metal halide, (D) at least one vanadium compound, and as the last step a second treatment with a Group IIIa metal halide.

Claim 3

The vanadium-containing catalyst component of claim 1 wherein the dihydrocarbyl magnesium compound is represented by the formula R 1 MgR 2 or a complex thereof with an aluminum compound, wherein each of R 1 and R 2 , which may be the same or different, are an alkyl group, aryl group, cycloalkyl group, aralkyl group having from 1 to 20 carbon atoms, the vanadium compound is represented by the general formulas: ##STR4## where x=0-3 and R=a hydrocarbon radical; VCl.sub.y (OR).sub.4-y, (2) where y=3-4 and R=a hydrocarbon radical; ##STR5## where z=2-3 and (AcAc)=acetyl acetonate group; ##STR6## where (AcAc)=acetyl acetonate group; and VCl.sub.3.nB, (5) where n=2-3 and B=a Lewis base which can form hydrocarbon-soluble complexes with VCl 3 ; and the Group III metal halides are selected from boron trichloride, boron hydrocarbyl halides and aluminum alkyl halides.

Claim 4

The vanadium-containing catalyst component of claim 2 wherein the Group III metal halides are selected from boron trichloride, ethyl aluminum dichloride and ethyl boron dichloride.

Claim 5

The vanadium-containing catalyst component of claim 1 wherein the inert solid support material is an inorganic oxide or mixtures of inorganic oxides.

Claim 6

The vanadium-containing catalyst component of claim 4 wherein the inorganic oxide is silica.

Claim 7

The vanadium-containing catalyst component of claim 2 wherein the vanadium compound is selected from vanadyl trichloride, vanadium tetrachloride, vanadyl tributoxy and vanadyl chloride dibutoxy.

Claim 8

The vanadium-containing catalyst component of claim 1 wherein the dihydrocarbyl magnesium compounds are selected from dialkyl magnesium compounds wherein the alkyl groups, which may be the same or different, can have 1 to 10 carbon atoms.

Claim 9

The vanadium-containing catalyst component of claim 2 wherein the oxygen-containing compound is selected from alcohols represented by the formula R 3 OH wherein R 3 can be an alkyl group, aryl group, cycloalkyl group, aralkyl group, alkadienyl group or alkenyl group having from 2 to 20 carbon atoms.

Claim 10

The vanadium-containing catalyst component of claim 8 wherein the dihydrocarbyl magnesium and the alcohol are reacted together prior to contact with the inert solid support material.

Claim 11

The vanadium-containing catalyst component of claim 8 wherein the dihydrocarbyl magnesium compound is contacted with the inert solid support material prior to the addition of the oxygen-containing compound.

Claim 12

The vanadium-containing catalyst component of claim 2 wherein the Group III metal halide is selected from boron trichloride and ethyl aluminum dichloride.

Claim 13

The vanadium-containing catalyst component of claim 11 wherein the Group III metal halide is ethyl aluminum dichloride.

Claim 14

A catalyst system for the polymerization of olefins comprising (A) an organo aluminum cocatalyst, and (B) the vanadium-containing catalyst component of claim 1.

Claim 15

A catalyst system for the polymerization of olefins comprising (A) an organo aluminum cocatalyst, and (B) the vanadium-containing catalyst component of claim 2.

Claim 16

A catalyst system for the polymerization of olefins comprising (A) an organo aluminum cocatalyst, and (B) the vanadium-containing catalyst component of claim 3.

Claim 17

A catalyst system for the polymerization of olefins comprising (A) an organo aluminum cocatalyst, and (B) the vanadium-containing catalyst component of claim 4.

Claim 18

A catalyst system for the polymerization of olefins comprising (A) an organo aluminum cocatalyst, and (B) the vanadium-containing catalyst component of claim 5.

Claim 19

A catalyst system for the polymerization of olefins comprising (A) an organo aluminum cocatalyst, and (B) the vanadium-containing catalyst component of claim 6.

Claim 20

A catalyst system for the polymerization of olefins comprising (A) an organo aluminum cocatalyst, and (B) the vanadium-containing catalyst component of claim 7.

Claim 21

A catalyst system for the polymerization of olefins comprising (A) an organo aluminum cocatalyst, and (B) the vanadium-containing catalyst component of claim 8.

Claim 22

A catalyst system for the polymerization of olefins comprising (A) an organo aluminum cocatalyst, and (B) the vanadium-containing catalyst component of claim 9.

Claim 23

A catalyst system for the polymerization of olefins comprising (A) an organo aluminum cocatalyst, and (B) the vanadium-containing catalyst component of claim 10.

Claim 24

A catalyst system for the polymerization of olefins comprising (A) an organo aluminum cocatalyst, and (B) the vanadium-containing catalyst component of claim 11.

Claim 25

A catalyst system for the polymerization of olefins comprising (A) an organo aluminum cocatalyst, and (B) the vanadium-containing catalyst component of claim 12.