Olefin polymerization catalyst and process

Claim 1

A method for preparing a particulate olefin polymerization catalyst component comprising forming a solution from components comprising a magnesium containing component and a transition metal containing component and then contacting the solution with the product resulting from the combination of an organoaluminum halide compound with a silicon compound to obtain said particulate catalyst component, wherein said magnesium-containing component is selected from one of the following groups: (1) oxygen-containing organomagnesium compounds (2) compounds having the formula RMgX wherein X is a halogen atom, and R is an alkyl, aryl, or cycloalkyl radical containing 1-20 carbon atoms, and (3) inorganic Mg halides, Mg oxide, Mg hydroxide, Mg hydroxyhalide, and Mg salts of inorganic oxygen containing acids, wherein said transition metal containing component is selected from Ti, V, or Zr compounds having at lest one OR" group wherein R" is hydrocarbyl groups selected from straight or branched chain alkyl groups, cycloalkyl groups, arylalkyl groups, aryl groups, and alkylaryl groups having 1 to 20 carbon atoms, wherein said organoaluminum halide is selected from compounds having the general formula AlR n X 3-n wherein each R is individually selected from saturated and unsaturated hydrocarbyl radicals containing 1 to 20 carbon atoms per radical, X is a halogen and n is any number in the range of 1 to 2, and wherein said silicon compound is selected from hydrocarbyloxy silane compounds having at least one Si--O--R group wherein R is a hydrocarbyl radical containing 1-20 carbon atoms and polysiloxane polymers having repeating units of the formula ##STR2## wherein each R is individually selected from alkyl groups having 1-12 carbon atoms and alkoxy groups having 1-12 carbon atoms.

Claim 2

A method for preparing a particulate olefin polymerization catalyst component comprising forming a solution from components comprising a magnesium containing component and a transition metal containing component and then contacting the solution with the product resulting from the combination of an organoaluminum halide compound with a silicon compound to obtain said particulate catalyst component, wherein said magnesium-containing component is selected from one of the following groups: (1) oxygen-containing organomagnesium compounds (2) compounds having the formula RMgX wherein X is a halogen atom, and R is an alkyl, aryl, or cycloalkyl radical containing 1-20 carbon atoms, and (3) inorganic Mg halides, Mg oxide, Mg hydroxide, Mg hydroxyhalide, and Mg salts of inorganic oxygen containing acids, wherein said transition metal containing component is selected from Ti, V, or Zr compounds having at lest one OR" group wherein R" is hydrocarbyl groups selected from straight or branched chain alkyl groups, cycloalkyl groups, arylalkyl groups, aryl groups, and alkylaryl groups having 1 to 20 carbon atoms, wherein said organoaluminum halide is selected from compounds having the general formula AlR n X 3-n wherein each R is individually selected from saturated and unsaturated hydrocarbyl radicals containing 1 to 20 carbon atoms per radical, X is a halogen and n is any number in the range of 1 to 2, and wherein said silicon compound is selected from hydrocarbyloxy silane compounds having at least one Si--O--R group wherein R is a hydrocarbyl radical containing 1-20 carbon atoms and polysiloxane polymers having repeating units of the formula ##STR2## wherein each R is individually selected from alkyl groups having 1-12 carbon atoms and alkoxy groups having 1-12 carbon atoms.

Claim 19

A method for preparing a particulate olefin polymerization catalyst comprising forming a solution from components comprising magnesium dichloride and titanium tetraethoxide and then contacting the solution with the product resulting from the combination of ethylaluminum sesquichloride and silicon tetraethoxide to obtain a particulate catalyst component, wherein the atomic ratio of the magnesium to the titanium is in the range of about 1:0.01 to about 1:20, the atomic ratio of the magnesium to the aluminum is in the range of about 1:0.1 to about 1:100, and wherein the silicon tetraethoxide is employed in an amount which provides an improvement in the particle size of the catalyst over a catalyst prepared without using said silicon tetraethoxide in combination with the ethylaluminum sesquichloride.

Claim 20

A method for preparing a particulate olefin polymerization catalyst comprising forming a solution from components comprising magnesium dichloride and titanium tetraethoxide and then contacting the solution with the product resulting from the combination of ethylaluminum sesquichloride and silicon tetraethoxide to obtain a particulate catalyst component, wherein the atomic ratio of the magnesium to the titanium is in the range of about 1:0.01 to about 1:20, the atomic ratio of the magnesium to the aluminum is in the range of about 1:0.1 to about 1:100, and wherein the silicon tetraethoxide is employed in an amount which provides an improvement in the particle size of the catalyst over a catalyst prepared without using said silicon tetraethoxide in combination with the ethylaluminum sesquichloride.

Claim 24

A method for preparing a particulate olefin polymerization catalyst comprising forming a solution from components comprising magnesium dichloride and titanium tetraethoxide and then contacting the solution with the product resulting from the combination of ethylaluminum sesquichloride and polysiloxane to obtain a particulate catalyst component, wherein the atomic ratio of the magnesium to the titanium is in the range to about 1:0.01 to about 1:20, the atomic ratio of the magnesium to the aluminum is in the range of about 1:0.1 to about 1:100, and wherein the polysiloxane employed in an amount which provides an improvement in the particle size of the catalyst over a catalyst prepared without using said polysiloxane combination with the ethylaluminum sesquichloride.

Claim 25

A method for preparing a particulate olefin polymerization catalyst comprising forming a solution from components comprising magnesium dichloride and titanium tetraethoxide and then contacting the solution with the product resulting from the combination of ethylaluminum sesquichloride and polysiloxane to obtain a particulate catalyst component, wherein the atomic ratio of the magnesium to the titanium is in the range to about 1:0.01 to about 1:20, the atomic ratio of the magnesium to the aluminum is in the range of about 1:0.1 to about 1:100, and wherein the polysiloxane employed in an amount which provides an improvement in the particle size of the catalyst over a catalyst prepared without using said polysiloxane combination with the ethylaluminum sesquichloride.