Process to prepare a procatalyst for polymerization of olefins

A process for the preparation of a procatalyst suitable for preparing a catalyst composition for olefin polymerization, said process comprising the steps of

• Step A) providing or preparing a compound R4zMgX42-z wherein:
• R4 is independently a linear, branched or cyclic hydrocarbyl group independently selected from alkyl, alkenyl, aryl, aralkyl, or alkylaryl groups, and one or more combinations thereof;
• wherein said hydrocarbyl group is substituted or unsubstituted, and optionally contains one or more heteroatoms;
• X4 is independently fluoride (F−), chloride (Cl−), bromide (Br−) or iodide (I−);
• and
• z is in a range of larger than 0 and smaller than 2, being 0<z<2;
• Step B) contacting the compound R4zMgX42-z with a silane compound Si(OR5)4-n(R6)n to give a solid support comprising Mg(OR1)xX12-x wherein:
• R1, R5 and R6 are each independently a linear, branched or cyclic hydrocarbyl group independently selected from alkyl, alkenyl, aryl, aralkyl, alkoxycarbonyl or alkylaryl groups, and one or more combinations thereof;
• wherein said hydrocarbyl group is substituted or unsubstituted, and optionally contains one or more heteroatoms;
• X1 is independently fluoride (F−), chloride (Cl−), bromide (Br−) or iodide (I−);
• n is in range of 0 to 4;
• and
• x is in a range of larger than 0 and smaller than 2, being 0<x<2;
• Step C) activating the solid support by contacting the solid support obtained in step B) with either at least one activation electron donor or with at least one first activating compound being a metal alkoxide or a metalloid alkoxide compound of formula M1(OR2)v-w(OR3)w or M2(OR2)v-w(R3)w;
• wherein:
• M1 is a metal or a metalloid selected from Ti, Zr, Hf, Al and Si;
• M2 is Si;
• v is the valency of M1 or M2;
• w is smaller than v;
• R2 and R3 are each a linear, branched or cyclic hydrocarbyl group independently selected from alkyl, alkenyl, aryl, aralkyl, alkoxycarbonyl or alkylaryl groups, and one or more combinations thereof;
• wherein said hydrocarbyl group is substituted or unsubstituted, and optionally contains one or more heteroatoms;
• and a second activating compound being an activating electron donor;
• to obtain an activated solid support;
• and
• Step D) adding to the activated solid support obtained in step C) toluene, a transition metal halide and at least one internal electron donor, and optionally also the addition of an activator prior to or simultaneous with the addition of an internal donor, and reacting to obtain the procatalyst;
• wherein step C) of activating the solid support, comprising two sub steps:
• Step C1) a first activation step of partly activating the solid support by contacting the solid support obtained in step B) with a second activating compound being an activating electron donor and with at least a first activating compound being a metal alkoxide or a metalloid alkoxide compound of formula M1(OR2)v-w(OR3)w or M2(OR2)v-w(R3)w;
• wherein M1 is a metal or a metalloid of Ti, Zr, Hf, Al or Si;
• M2 is Si;
• v is the valency of M1 or M2;
• w is smaller than v;
• R2 and R3 are each a linear, branched or cyclic hydrocarbyl group independently selected from alkyl, alkenyl, aryl, aralkyl, alkoxycarbonyl or alkylaryl groups, and one or more combinations thereof;
• wherein said hydrocarbyl group is substituted or unsubstituted, and optionally contains one or more heteroatoms;
• and step C2) a second activation step by contacting the partly activated solid support obtained in step C1) with an activating electron donor to obtain an activated solid support.