Preparation of a magnesium halide support for olefin polymerization and a catalyst composition using the same

Abstract

A magnesium halide support material for a polyolefin catalysts is disclosed. The magnesium halide of present invention is prepared by reacting magnesium with an alkylhalide in a non-polar hydrocarbon solvent. Preparation of the support does not require the use electron donating solvents and therefore does not require extensive washing to remove the solvent from the support.

1 . A magnesium halide support for an olefin polymerization catalyst, wherein the magnesium halide support is prepared by: 
 providing magnesium and an alkylhalide in a non-polar hydrocarbon medium;    providing a metal complex having the formula M(OR) n Cl m  to the non-polar hydrocarbon medium to initiate a reaction between the magnesium and the alkylhaide, wherein M is Zirconium or aluminum, n is from 1 to 4 and m is from 0 to 3, and R is a hydrocarbon; and    recovering the magnesium halide support.    
   
   
       2 - 6 . (canceled)  
   
   
       7 . A process for preparing a solid support for an olefin polymerization catalyst comprising: 
 combining magnesium and an alkylhalide in a non-polar hydrocarbon medium;    providing a metal complex having the formula M(OR) n X m  to the non-polar hydrocarbon medium to initiate a reaction between the magnesium and the alkylhalide, wherein M is zirconium or aluminum, n is from 1 to 4, m is from 0 to 3, R is alkyl, X is halide; and    recovering the solid support.    
   
   
       8 . The process for preparing a solid support of  claim 7  wherein the recovered solid support consists essentially of a mixed alkoxy halide of magnesium and M.  
   
   
       9 . The process for preparing a solid support of  claim 7  wherein M is zirconium and the metal complex is obtained by the reaction between a zirconium halide represented by formula ZrX 4  with an alcohol represented by formula ROH; wherein the molar ratio of alcohol to zirconium is about 1 to about 6, wherein R is alkyl, and X is halide.  
   
   
       10 . The process for preparing a solid support of  claim 7  wherein the metal complex is an aluminum alkoxide compound represented by formula Al(OR) 3 .  
   
   
       11 . The process for preparing a solid support of  claim 7  wherein the molar ratio of metal complex to magnesium in the hydrocarbon medium is about 0.01 to about 0.3.  
   
   
       12 . The process for preparing a solid support of  claim 7  wherein M is zirconium and the molar ratio of alkylhalide to magnesium is about 0.5 to about 3.0.  
   
   
       13 . The process for preparing a solid support of  claim 7  wherein M is aluminum and the molar ratio of alkylhalide to magnesium is about 1.0 to about 3.0.