Solution process for the preparation of polymers of alpha-olefins

Claim 1

In a solution process for the preparation of high molecular weight polymers of alpha-olefins selected from the group consisting of homopolymers of ethylene and copolymers of ethylene and C 3 -C 12 alpha-olefins, said process comprising feeding monomer selected from the group consisting of ethylene and mixtures of ethylene and at least one C 3 -C 12 alpha-olefin, a coordination catalyst and inert hydrocarbon solvent to a reactor, polymerizing said monomer at a temperature in the range of 105°-320° C. and recovering the polymer so obtained by a sequence of steps of deactivating the catalyst in the solution obtained from the reactor by sequentially admixing therewith a minor amount of water followed by a solution of a salt of an alkaline earth metal or zinc and an aliphatic carboxylic acid dissolved in hydrocarbon solvent, separating the hydrocarbon solvent and other volatile matter from the resultant solution and recovering a composition comprising said high molecular weight polymer, the amount of water being 0.25-1.5 moles of water per mole of chlorine plus alkyl radicals plus R 2 AlO-groups in the coordination catalyst; said coordination catalyst having been obtained by combining a first component with a second component, said first component being prepared by a method selected from the group consisting of (i) admixing a solution of an organoaluminum compound in inert hydrocarbon solvent with a solution of titanium tetrachloride and vanadium oxytrichloride in inert hydrocarbon solvent at a temperature of less than 30° C. and heating the resultant admixture to a temperature of 150°-300° C. for a period from 5 seconds to 60 minutes and (ii) admixing a solution of an organoaluminum compound in inert hydrocarbon solvent with a solution of titanium tetrachloride in inert hydrocarbon solvent at a temperature of less than 30° C., heating the resultant admixture to a temperature of 150°-300° C. for a period of from 5 seconds to 60 minutes and admixing vanadium oxytrichloride with the admixture so obtained, said organoaluminum compound being of the formula AlR n X 3-n and being admixed with the titanium and vanadium compounds so that the atomic ratio of aluminum in the first component to titanium plus vanadium is in the range of 0.2-2.0 where R is alkyl and has 1-20 carbon atoms; n=1, 1.5, 2, or 3 and X is halogen, said catalyst components being mixed in-line and fed to the reactor without separation of any component thereof, the improvement wherein the second component is a solution of an aluminoxane in inert hydrocarbon solvent, and the aluminoxane is selected from the group consisting of (i) aluminoxanes of the formula R'AlO(R'AlO) m -AlR' 2 , where each R' is independently selected from alkyl and cycloalkyl having 1-20 carbon atoms and m is 0 or an integer, and (ii) cyclic aluminoxanes of the formula ##STR2## where each R" is independently selected from alkyl and cycloalkyl of 1-20 carbon atoms and m is an integer having a value of at least 2, the ratio of aluminoxane to titanium plus vanadium in the second component being in the range of 0.9-10 on a molar basis.