Vanadium-containing catalyst system

Claim 2

A vanadium-containing catalyst system comprising: (A) a supported catalyst component prepared by the steps of (a) preheating silica at a temperature in the range of between about 150° C. and about 800° C.; (b) contacting said preheated silica with a contacting agent selected from the group consisting of (1) a compound or complex which includes at least one carbon to magnesium covalent bond, (2) a compound which includes at least one carbon to a metal of Group III of the Periodic Table of the Elements covalent bond and (3) both a compound or complex which includes at least one carbon to magnesium covalent bond and a compound which includes at least one carbon to Group III metal covalent bond; (c) contacting said product of step (b) with whichever of contacting agent (1) and (2) that does not contact said preheated silica in step (b), with the proviso that this step is omitted if said contacting agent (3) is employed in step (b); (d) contacting said product of step (b) or (c) with a vanadium compound which includes at least one halogen atom; and (e) contacting said product of step (d) with an alcohol; (B) an organoaluminum compound cocatalyst; and (C) a halogen-containing promoter compound having the structural formula C t H s X 2t+2-s 2 where X 2 is the same or different and is fluorine, chlorine or bromine; t is an integer of 1 to 3 and s is 0 or an integer of 1 to 7.

Claim 3

A catalyst system in accordance with claim 1 wherein said silica is preheated to a temperature in the range of between about 150° C. and about 400° C.

Claim 4

A catalyst system in accordance with claim 2 wherein said silica is preheated to a temperature in the range of between about 200° C. and about 300° C.

Claim 5

A catalyst system in accordance with claim 1 wherein said compound (1) has the structural formula MgR.sub.2.nAlR.sup.1.sub.3 where R is the same or different and is hydrocarbyl; R 1 is the same or different and is hydrocarbyl; and n is 0 to about 1.

Claim 6

A catalyst system in accordance with claim 4 where R is the same or different and is C 1 -C 8 alkyl; R 1 is the same or different and is C 1 -C 8 alkyl; and n is 0 to about 0.7.

Claim 7

A catalyst system in accordance with claim 5 wherein R is the same and is n-butyl; R 1 is the same and is ethyl; and n is 0 or about 0.133.

Claim 8

A catalyst system in accordance with claim 1 wherein said Group III metal of said compound (2) is aluminum.

Claim 9

A catalyst system in accordance with claim 7 wherein said compound (2) has the structural formula AlR.sup.2 R.sup.3 R.sup.4 where R 2 , R 3 and R 4 are the same or different and are hydrocarbyl.

Claim 10

A catalyst system in accordance with claim 8 wherein R 2 , R 3 and R 4 are the same or different and are C 2 -C 6 alkyl.

Claim 11

A catalyst system in accordance with claim 9 wherein said compound (2) is triethylaluminum.

Claim 12

A catalyst system in accordance with claim 1 wherein said vanadium compound which includes at least one halogen atom is selected from the group consisting of (R.sup.5 O).sub.p VO.sub.m X.sub.3-p (i) where R 5 is C 1 -C 12 hydrocarbyl; X is halogen; m is 0 or 1 and p is 0, 1 or 2; and (R.sup.5 O).sub.q VX.sub.4-q (ii) where q is 0, 1, 2 or 3; and R 5 and X have the meanings given above.

Claim 13

A catalyst system in accordance with claim 11 where p and q are 0; and X is chlorine or bromine.

Claim 14

A catalyst system in accordance with claim 1 wherein said alcohol has the structural formula R 6 OH, where R 6 is hydrocarbyl.

Claim 15

A catalyst system in accordance with claim 13 wherein R 6 is C 1 -C 12 alkyl.

Claim 16

A catalyst system in accordance with claim 14 wherein R 6 is n-butyl.

Claim 17

A catalyst system in accordance with claim 1 wherein said component (B) is a compound having the structural formula AlR.sup.7.sub.r X.sup.1.sub.3-r where R 7 is the same or different and is hydrocarbyl; X 1 is halogen; and r is an integer of 1 to 3.

Claim 18

A catalyst system in accordance with claim 16 wherein R 7 is the same or different and is C 1 -C 8 alkyl; and X 1 is chlorine or bromine.

Claim 19

A catalyst system in accordance with claim 17 wherein R 7 is the same or different and is C 1 -C 4 alkyl; and r is 3.

Claim 20

A catalyst system in accordance with claim 1 wherein said component (C) is selected from the group consisting of carbon tetrachloride, carbon tetrabromide, dichloromethane, dibromomethane, chloroform, tribromomethane, 1,1,1-trichloroethane, 2,2-difluorotetrachloroethane, 1-dichlorofluoro-3-difluorochloropropane, methyl bromide, 1,1-dichloro-2,2,2-trifluoroethane, dichlorofluoromethane, trichlorofluoromethane and heptachloropropane.

Claim 21

A catalyst system in accordance with claim 1 wherein said components (A) and (B) are present in concentrations such that the molar ratio of aluminum in said component (B) to vanadium in said component (A) is in the range of between about 10:1 and about 100:1.

Claim 22

A catalyst system in accordance with claim 20 wherein component (B) and component (C) are present such that the molar ratio of aluminum in said component (B) to the number of moles of said halogen-containing promoter compound of said component (C) is in the range of between about 0.05:1 and about 20.0:1.

Claim 23

A catalyst system in accordance with claim 21 wherein said molar ratio of aluminum in said component (B) to vanadium in said component (A) is in the range of between about 15:1 and about 80:1; and said molar ratio aluminum in said component (B) to the number of moles of said halogen-containing promoter compound of said component (C) is in the range of between about 0.5:1 and about 3.0:1.

Claim 24

A catalyst system in accordance with claim 22 wherein said molar ratio of aluminum in said component (B) to vanadium in said component (A) is in the range of between about 20:1 and about 60:1; and said molar ratio of aluminum in said component (B) to the number of moles of said halogen-containing promoter compound of said component (C) is in the range of between about 0.50:1 and about 2.0:1.

Claim 25

A catalyst system in accordance with claim 23 wherein said vanadium compound used in the formation of component (A) is vanadium tetrachloride, said organoaluminum compound of component (B) is triethylaluminum and said halogen-containing promoter compound of component (C) is dibromomethane.

Claim 26

A vanadium-containing catalyst system which comprises (A) a catalyst component formed by the steps which comprise: (a) preheating silica particles to a temperature in the range of between about 200° C. and about 300° C.; (b) disposing said preheated silica particles in an inert hydrocarbon liquid under ambient conditions, whereby a slurry is formed; (c) contacting said slurry with a contacting agent selected from the group consisting of (1) a compound or complex which includes at least one carbon to magnesium covalent bond, (2) a compound which includes at least one carbon to metal of Group III of the Periodic Table of the Elements covalent bond and (3) a mixture thereof wherein said compound or complex (1) is introduced into the slurry at a concentration in the range of between about 0.1 millimole and about 2.0 millimoles of magnesium of said compound or complex (1) per gram of silica and/or said compound (2) is introduced into said slurry at a concentration in the range of between about 0.1 millimole and about 2.0 millimoles of Group III metal of said compound (2) per gram of silica; (d) contacting the product of step (c) with whichever of compound or complex (1) and compound (2) does not contact said preheated silica in step (c), said concentration of said compound or complex (1) or compound (2) per gram of silica being the concentration of that compound recited in said step (c), with the proviso that this step is omitted if (3) a mixture of compound or complex (1) and compound (2) is introduced into said slurry in step (c); (e) contacting the product of step (c) or (d) with a vanadium compound which includes at least one halogen atom in a concentration such that between about 0.2 millimole and about 2.0 millimoles of vanadium are present per gram of silica; and (f) contacting the product of step (e) with an alcohol in a concentration such that between about 0.1 millimole and about 2.0 millimoles of alcohol are present per gram of silica; (B) an organoaluminum compound cocatalyst; and (C) a halogen-containing promoter compound having the structural formula C t H s X 2t+2-s 2 where X 2 is the same or different and is fluorine, chlorine or bromine; t is an integer of 1 to 3; and s is 0 or an integer of 1 to 7.

Claim 27

A vanadium-containing catalyst system which comprises (A) a catalyst component formed by the steps which comprise: (a) preheating silica particles to a temperature in the range of between about 200° C. and about 300° C.; (b) disposing said preheated silica particles in an inert hydrocarbon liquid under ambient conditions, whereby a slurry is formed; (c) contacting said slurry with a contacting agent selected from the group consisting of (1) a compound or complex which includes at least one carbon to magnesium covalent bond, (2) a compound which includes at least one carbon to metal of Group III of the Periodic Table of the Elements covalent bond and (3) a mixture thereof wherein said compound or complex (1) is introduced into the slurry at a concentration in the range of between about 0.1 millimole and about 2.0 millimoles of magnesium of said compound or complex (1) per gram of silica and/or said compound (2) is introduced into said slurry at a concentration in the range of between about 0.1 millimole and about 2.0 millimoles of Group III metal of said compound (2) per gram of silica; (d) contacting the product of step (c) with whichever of compound or complex (1) and compound (2) does not contact said preheated silica in step (c), said concentration of said compound or complex (1) or compound (2) per gram of silica being the concentration of that compound recited in said step (c), with the proviso that this step is omitted if (3) a mixture of compound or complex (1) and compound (2) is introduced into said slurry in step (c); (e) contacting the product of step (c) or (d) with a vanadium compound which includes at least one halogen atom in a concentration such that between about 0.2 millimole and about 2.0 millimoles of vanadium are present per gram of silica; and (f) contacting the product of step (e) with an alcohol in a concentration such that between about 0.1 millimole and about 2.0 millimoles of alcohol are present per gram of silica; (B) an organoaluminum compound cocatalyst; and (C) a halogen-containing promoter compound having the structural formula C t H s X 2t+2-s 2 where X 2 is the same or different and is fluorine, chlorine or bromine; t is an integer of 1 to 3; and s is 0 or an integer of 1 to 7.

Claim 28

A catalyst system in accordance with claim 25 wherein said compound or complex (1) has the structural formula MgR.sub.2.nAlR.sup.1.sub.3 where R is the same or different and is hydrocarbyl; R 1 is the same or different and is hydrocarbyl; and n is 0 to about 1, and is present in a concentration in the range of between about 0.4 millimole and about 1.4 millimoles of magnesium per gram of silica.

Claim 29

A catalyst system in accordance with claim 26 wherein said compound (2) has the structural formula AlR 2 R 3 R 4 , where R 2 , R 3 and R 4 are the same or different and are alkyl, and is present in a concentration in the range of between about 0.4 millimole and about 1.4 millimoles of aluminum per gram of silica.

Claim 30

A catalyst system in accordance with claim 27 wherein said vanadium compound is selected from the group consisting of VOCl 3 , VOBr 3 , VCl 4 , VBr 4 , VCl 3 and VBr 3 and is present in a concentration in the range of between about 0.4 millimole and about 1.2 millimoles of vanadium per gram of silica.

Claim 31

A catalyst system in accordance with claim 28 wherein said vanadium compound and said alcohol is present such that the molar ratio of said alcohol to said vanadium compound is no more than about 1.

Claim 32

A catalyst compound in accordance with claim 29 wherein said molar ratio of said alcohol to said vanadium compound is in the range of between about 0.05:1 and about 1:1.

Claim 33

A catalyst system in accordance with claim 30 wherein said alcohol has the structural formula R 6 OH, where R 6 is C 1 -C 12 alkyl and is present in a concentration in the range of between about 0.15 millimole and about 1.0 millimole per gram of silica.

Claim 34

A catalyst system in accordance with claim 31 wherein said inert hydrocarbon liquid is a C 5 to C 8 alkane.

Claim 35

A catalyst system in accordance with claim 32 wherein said compound or complex (1) is present in a concentration in the range of between about 0.6 millimole and about 1.0 millimole of magnesium per gram of silica and wherein R is n-butyl; R 1 is ethyl; and n is 0 or 0.133.

Claim 36

A catalyst system in accordance with claim 33 wherein said compound (2) is present in a concentration in the range of between about 0.6 millimole and about 1.0 millimole of aluminum per gram of silica and wherein R 2 , R 3 and R 4 are the same and are ethyl.

Claim 37

A catalyst system in accordance with claim 34 wherein said vanadium compound is selected from the group consisting of VOCl 3 , VCl 4 and VCl 3 and is present in a concentration in the range of between about 0.6 millimole and about 0.9 millimole of vanadium per gram of silica.

Claim 38

A catalyst system in accordance with claim 35 wherein said molar ratio of said alcohol to said vanadium compound is in the range of between about 0.1:1 and about 0.6:1.

Claim 39

A catalyst system in accordance with claim 36 wherein said alcohol is characterized by R 6 being C 1 -C 8 alkyl and by being present in a concentration in the range of between about 0.2 millimole and about 0.8 millimole per gram of silica.

Claim 40

A catalyst system in accordance with claim 37 wherein R 6 is C 2 -C 6 alkyl and said molar ratio of said alcohol to said vanadium compound is in the range of between about 0.2:1 and about 0.3:1.

Claim 41

A catalyst system in accordance with claim 38 wherein said compound or complex (1), said compound (2), said vanadium compound and said alcohol is introduced into said slurry as a solution wherein the solvent is an alkane identical to said inert hydrocarbon liquid slurrying agent.

Claim 42

A catalyst system in accordance with claim 39 wherein inert hydrocarbon liquid slurrying agent and solvent is heptane.

Claim 43

A catalyst system in accordance with claim 40 wherein said step (b) involves contact with said compound or complex (1) and said step (c) involves contact with said compound (2).

Claim 44

A catalyst system in accordance with claim 40 wherein said step (b) involves contact with said compound (2) and said step (c) involves contact with said compound or complex (1).

Claim 45

A catalyst system in accordance with claim 40 wherein said step (b) involves contact with (3) a mixture of said compound or complex (1) and said compound (2); and wherein said step (c) is omitted.

Claim 46

A catalyst system in accordance with claim 1 wherein said component (C) is trichlorofluoromethane or dibromomethane.

Claim 47

A catalyst system in accordance with claim 44 wherein said component (C) is dibromomethane.

Claim 48

A catalyst system in accordance with claim 25 wherein component (C) is trichlorofluoromethane or dibromomethane.

Claim 49

A catalyst system in accordance with claim 46 wherein said component (C) is dibromomethane.