# US 7,608,555 B2 · Method for the preparation of olefin polymerization catalysts > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,608,555 B2 - Document ID: US7608555B2 - Status: Granted - Kind: B2 - Application number: 11/759,086 - Filed: 2007-06-06 - Published: 2007-10-25 - Granted: 2009-10-27 - Earliest claimed: 2002-06-18 - Assignees: Borealis Technology Oy - Inventors: Thomas Garoff; Kari Pesonen; Päivi Waldvogel; Timo V. Laine; Peter Denifl; Jarmo Lindroos - Web page: https://patentgrep.com/patent/US7608555B2 ## CPC - C08F 10/00: Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond - C08F 2410/06: Catalyst characterized by its size - C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS ## Abstract The present invention relates to a process for the production of catalysts, particularly of Ziegler-Natta type of catalysts for olefin polymerisation, to the catalysts as such, and to their use in polymerising olefins. ## Claims ### Claim 1 A process for producing an olefin polymerization catalyst precursor comprising a catalyst component formed by contacting at least (a) a compound of Group 1 to 3 of the Periodic Table (IUPAC) with (c1) a chlorine-containing compound of Group 13 of the Periodic table (IUPAC), in the form of solid particles, said process comprising: (1) preparing a solution from said compounds; (2) dispersing said solution to a media immiscible therewith and inert in relation to the compounds, to obtain an emulsion in which said solution forms the dispersed phase; and (3) solidifying the catalyst component in the dispersed droplets. ### Claim 2 (depends on 1) The process of claim 1, wherein an inert solvent is used for the preparation of said solution, which solvent is selected from a linear or cyclic alkane or alkene, an aromatic hydrocarbon or a halogen-containing hydrocarbon, and a mixture thereof. ### Claim 3 (depends on 1) The process of claim 1, wherein the inert, immiscible media constituting the continuous phase comprises a fluorinated organic solvent or a mixture thereof. ### Claim 4 (depends on 3) The process of claim 3, wherein said fluorinated organic media comprises a semi or perfluorinated organic solvent, a functionalized derivative thereof or a mixture thereof. ### Claim 5 (depends on 4) The process of claim 4, wherein said fluorinated organic media comprises a perfluorohydrocarbon, functionalized derivative thereof or a mixture thereof. ### Claim 6 (depends on 1) The process of claim 1, wherein said emulsion comprising said continuous phase and said dispersed phase is a bi- or multiphasic system. ### Claim 7 (depends on 1) The process of claim 1, wherein the solidification of the catalyst component is effected by reacting the compounds present in the droplets dispersed in said inert continuous phase. ### Claim 8 (depends on 1) The process of claim 1, wherein the solidification of the catalyst component is effected by dispersing the solution from the compounds (a) and (c1) to said inert media, and by subjecting the formed emulsion to a temperature change. ### Claim 9 (depends on 8) The process of claim 8, wherein said temperature change treatment comprises subjecting the emulsion to gradual temperature change of up to 10° C. per minute. ### Claim 10 (depends on 1) The process of claim 1, wherein the formed emulsion system is further dispersed into an inert receiving medium with a different temperature to cause a rapid solidification of the dispersed catalyst component. ### Claim 11 (depends on 10) The process of claim 10, wherein the formed emulsion system is dispersed into said inert receiving medium with a temperature change of more than 40° C. within less than 10 seconds. ### Claim 12 (depends on 1) The process according to claim 1, wherein the dispersed phase is formed from a solution prepared by contacting (a) a compound of a Group 2 metal of the Periodic Table (IUPAC), with (c1) a compound of a Group 13 metal of the Periodic Table (IUPAC). ### Claim 13 (depends on 12) A process according to claim 12, wherein said compound of a Group 2 metal of the Periodic Table (IUPAC) is a Mg compound, said compound of a Group 13 metal of the Periodic Table (IUPAC) is an Al compound. ### Claim 14 (depends on 1) The process of claim 1, wherein said compound (a) is prepared by reacting Mg(R2)2 with an alcohol R1OH, wherein R1 and each R2 is independently a hydrocarbyl radical selected from linear or branched alkyl radicals having 1 to 20 carbon atoms, to obtain a compound of the formula Mg(OR1)2−nR2n, wherein 0≦n<2 and wherein R1 and R2 are as defined before. ### Claim 15 (depends on 14) The process of claim 14, wherein said Mg(R2)2 is magnesium butyloctyl. ### Claim 16 (depends on 14) The process of claim 14, wherein said R1OH is a branched alcohol having 5 to 10 carbon atoms. ### Claim 17 (depends on 14) The process of claim 14, wherein the catalyst component is formed by reacting a magnesium dialkyl compound, an alcohol, and an alkyl aluminum halide in the droplets dispersed in said inert continuous phase. ### Claim 18 (depends on 17) The process of claim 17, wherein the catalyst component is formed by reacting a magnesium dialkyl with an alcohol of formula R1OH, wherein R1 is a linear or branched C2-10 alkyl, and adding to the obtained solution ethyl aluminum dichloride. ### Claim 19 (depends on 14) The process of claim 14, wherein the catalyst component is formed by reaction of an alkyl aluminum chloride with a magnesium alkoxide formed by reacting a magnesium dialkyl with an alcohol of formula R1OH, wherein R1 is a linear, cyclic or branched C3-10 alkyl, and thereafter washing the obtained solid particles and treating said particles with a titanium compound. ### Claim 20 (depends on 1) The process of claim 1, further comprising the step of (4) recovering the solid particles. ### Claim 21 (depends on 5) The process of claim 5, wherein the perfluorohydrocarbon, is selected from perfluoroalkanes, perfluoroalkenes, and perfluorocycloalkanes. ### Claim 22 (depends on 21) The process of claim 21, wherein the perfluoroalkane is a C3-C30 Perfluoroalkane, the perfluoroalkene is a C3-C30 periluoroalkene, and perfluorocycloalkane is a C3-C30 perfluorocycloalkane. ### Claim 23 (depends on 21) The process of claim 21, wherein the perfluoroalkane is a C4-C10 perfluoroalkane, the perfluoroalkene is a C4-C10 perfluoroalkene, and the perfluorocycloalkane is a C4-C10 perfluorocycloalkane. ### Claim 24 (depends on 21) The process of claim 21, wherein the perfluorohydrocarbon is selected from perfluorohexane, perfluoroheptane, periluorooctane, perfluoro(methylcyclohexane), and mixtures thereof. ### Claim 25 (depends on 9) The process of claim 9, wherein the gradual temperature change is 0.5-6° C. per minute. ### Claim 26 (depends on 25) The process of claim 25, wherein the gradual temperature change is 1-5° C. per minute. ### Claim 27 (depends on 11) The process of claim 11, wherein the temperature change is more than 50° C. within less than 6 seconds. ### Claim 28 (depends on 19) The process of claim 19, wherein said R1OH is 2-ethyl hexanol.