Olefin polymerization catalyst compositions and a process for the polymerization of olefins employing such compositions

A solid component for olefin polymerization catalyst compositions which component has been obtained by halogenating a magnesium compound of the formula MgR'R" wherein R' is an alkyl or aryl group and R" is an alkyl or aryl group or halogen, with a halide of tetravalent titanium in the presence of a halohydrocarbon and an electron donor, contacting the halogenated product with a tetravalent titanium compound, and recovering the solid reaction product.

A solid component for olefin polymerization catalyst compositions, containing titanium and magnesium in an atomic ratio of Ti:Mg in the range from 0.02:1 to 1:1, which component has been obtained by contacting a compound MgR'R", in which R' and R" are alkyl groups of 2 to 8 carbon atoms, in a first contacting step with titanium tetrachloride, a chlorohydrocarbon having 1 to 12 carbon atoms per molecule and an electron donor, resulting in a solid which contains Mg, Ti, Cl and electron donor and which has an Mg:Cl atomic ratio of at least 1.5, contacting the resulting solid with titanium tetrachloride in a second contacting step and recovering the solid reaction product.

A solid component for olefin polymerization catalyst compositions, containing titanium and magnesium in an atomic ratio of Ti:Mg in the range from 0.02:1 to 1:1, which component has been obtained by converting a compound MgR'R" in which R' and R" are alkyl groups of 2 to 8 carbon atoms to magnesium dichloride by reaction with titanium tetrachloride in a molar ratio of MgR'R":titanium tetrachloride in the range from 0.01:1 to 1.0:1 in a first contacting step in the presence of a chlorohydrocarbon having 1 to 12 carbon atoms per molecule and of an aromatic ester electron donor, resulting in a solid which contains Mg, Ti, Cl and electron donor, contacting the resulting solid with titanium tetrachloride in a second contacting step, and recovering the solid reaction product.

An olefin polymerization catalyst composition comprising (a) a reaction product of an organoaluminum compound and an electron donor, and (b) a solid component which has been obtained by halogenating a magnesium compound of the formula MgR'R" wherein R' is an alkyl or aryl group and R" is an alkyl or aryl group or halogen, with a halide of tetravalent titanium in the presence of a halohydrocarbon, contacting the halogenated product with a tetravalent titanium compound, and recovering the solid reaction product.

An olefin polymerization catalyst composition comprising (a) a reaction product of an organoaluminum compound and an electron donor, and (b) a solid component which has been obtained by halogenating a magnesium compound of the formula MgR'R" wherein R' is an alkyl or aryl group and R" is an alkyl or aryl group or halogen, with a halide of tetravalent titanium in the presence of a halohydrocarbon and an electron donor, contacting the halogenated product with a tetravalent titanium compound and recovering the solid reaction product.

A method for the preparation of a solid component for olefin catalyst compositions, comprising halogenating a magnesium compound of the formula MgR'R" wherein R' is an alkyl or aryl group and R" is an alkyl or aryl group or halogen, with a halide of tetravalent titanium in the presence of a halohydrocarbon and an electron donor, separating the solid reaction product from the reaction mixture, optionally washing it with an inert diluent to remove any unreacted material, then contacting the halogenated product with a tetravalent titanium compound in a second contacting step, separating the resulting solid from the liquid medium, and washing it with an inert diluent to remove all unreacted titanium compound.

A method for the preparation of a solid component for olefin catalyst compositions, comprising contacting a compound MgR'R", in which R' and R" are alkyl groups of 2 to 8 carbon atoms, in a first contacting step with titanium tetrachloride, a chlorohydrocarbon having 1 to 12 carbon atoms per molecule and an electron donor, resulting in a solid which contains Mg, Ti, Cl and electron donor and which has an Mg:Cl atomic ratio of at least 1.5, separating the solid reaction product from the reaction mixture, optionally washing it with an inert diluent to remove any unreacted material, then contacting the resulting solid with titanium tetrachloride in a second contacting step, separating the resulting solid from the liquid medium, and washing it with an inert diluent to remove all unreacted titanium compound.

A method for the preparation of a solid component for olefin polymerization catalyst compositions, comprising converting a compound MgR'R" in which R' and R" are alkyl groups of 2 to 8 carbon atoms to magnesium dichloride by reaction with titanium tetrachloride in a molar ratio of MgR'R":titanium tetrachloride in the range from 0.01:1 to 1.0:1 in a first contacting step in the presence of a chlorohydrocarbon having 1 to 12 carbon atoms per molecule and of an aromatic ester electron donor, resulting in a solid which contains Mg, Ti, Cl and electron donor, separating the solid reaction product from the reaction mixture, optionally washing it with an inert diluent to remove any unreacted material, then contacting the resulting solid with titanium tetrachloride in a second contacting step, separating the resulting solid from the liquid medium, and washing it with an inert diluent to remove all unreacted titanium compound.