Ziegler-natta catalyst

Abstract

The present invention relates generally to catalysts, to methods of making catalysts, to methods of using catalysts, to methods of polymerizing, and to polymers made with such catalysts. More particularly, the present invention relates to polyolefin catalysts and to Ziegler-Natta catalysts, to methods of making such catalysts, to methods of using such catalysts, to polyolefin polymerization, and to polyolefins.

1 . (canceled) 
     
     
         2 . The catalyst of  claim 15 , wherein the alkyl magnesium compound is represented by the formula MgR 1 R 2 , wherein R 1  and R 2  are independently selected from C 1  to C 10  alkyls. 
     
     
         3 . The catalyst of  claim 15 , wherein the alkyl magnesium compound is selected from butyl ethyl magnesium, diethyl magnesium, dipropyl magnesium, dibutyl magnesium and combinations thereof. 
     
     
         4 . The catalyst of  claim 15 , wherein the alcohol contacts the alkyl magnesium compound in an equivalent of from about 0.5 to about 6. 
     
     
         5 . The catalyst of  claim 15 , wherein the alcohol is represented by the formula R 3 OH, wherein R 3  is selected from C 2  to C 20  alkyls. 
     
     
         6 . The catalyst of  claim 15 , wherein the reaction product B is not further contacted with metal halide before being contacted with organoaluminum compound. 
     
     
         7 . The catalyst of  claim 15 , wherein R′ and R″ are independently selected from C 2 -C 8  alkyls which may be linear, branched, aromatic or cyclic. 
     
     
         8 . The catalyst of  claim 15 , wherein the first and second compounds are blended before being contacted with the magnesium dialkoxide. 
     
     
         9 . The catalyst of  claim 15 , wherein A is titanium for both the first and second compounds. 
     
     
         10 . The catalyst of  claim 15 , wherein the plurality of firsts agents consists essentially of the first, second and third compounds. 
     
     
         11 . The catalyst of  claim 15 , wherein the plurality of first agents is added to the alkyl magnesium compound in an equivalent of from about 2 to about 4. 
     
     
         12 . The catalyst of  claim 15 , wherein the first compound comprises tetra n-butyl-titanate, and the second compound comprises titanium isopropoxide. 
     
     
         13 . The catalyst of  claim 15 , wherein the second compound comprises tetra n-butyl-titanate, and the first compound comprises titanium isopropoxide. 
     
     
         14 . The catalyst of  claim 15 , wherein for the first and/or second compound R′ and R″ are a C 3  alkyl. 
     
     
         15 . A catalyst formed from a process of forming the catalyst comprising:
 contacting an alkyl magnesium compound with alcohol to form a magnesium dialkoxide compound;   contacting the magnesium dialkoxide compound with a plurality of first agents to thereby form a solid reaction product “A”, wherein the plurality of first agents comprises a first compound, a second compound, and a third compound; wherein the first and second compounds are independently represented by the formula: A(O x R′X q   1 ) y (O x R″X p   2 ) z  wherein A is independently selected from titanium, silicon, aluminum, carbon, tin and germanium; X 1  and X 2  are optional and when one and/or the other are present, they are the same or different heteroatoms; R′ and R″ are independently selected from C 1 -C 10  alkyls which may be linear, branched, aromatic or cyclic; x is 0 or 1; and y+z is the valence of A; wherein the first and second compounds are contacted with the magnesium dialkoxide in the substantial absence of metal halide; and wherein the third compound is contacted last and consists essentially of unblended TiCl 4 ;   contacting reaction product “A” with a second agent to form reaction product “B”, wherein the second agent comprises a metal halide; and   contacting reaction product “B” with a third agent to form a catalyst, wherein the third agent comprises an organoaluminum compound.   
     
     
         16 . (canceled) 
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . The catalyst of  claim 20 , wherein A is titanium for both the first and second compounds. 
     
     
         20 . A catalyst comprising a precursor, wherein the precursor is formed by a process consisting essentially of:
 contacting, in a single reagent or mixture of reagents, a magnesium dialkoxide compound with a plurality of unblended compounds to thereby precipitate a solid catalyst precursor, wherein the first and second compounds are independently represented by the formula: A(O x R′X q   1 ) y (O x R″X p   1 ) z  wherein A is independently from titanium, silicon, aluminum, carbon, tin and germanium; X 1  and X 2  are optional and when one and/or the other are present, they are the same or different heteroatoms; R′ and R″ are independently selected from C 2 -C 8  which may be branched, linear, cyclic or aromatic; x is 0 or 1; and y+z is the valence of A; wherein the first and second compounds are contacted with the magnesium dialkoxide in the substantial absence of metal halide; and wherein the third compound is contacted last and is TiCl 4 .   
     
     
         21 . The catalyst of  claim 20 , wherein both R′ and R″ are a C 3  alkyl. 
     
     
         22 . The catalyst of  claim 20 , wherein the first and/or second compound is tetra n-butyl titanate. 
     
     
         23 . The catalyst of  claim 20 , wherein the first and/or second compound is titanium isopropoxide. 
     
     
         24 . The catalyst of  claim 20 , wherein the reagent is selected from substituted and unsubstituted aromatic and aliphatic hydrocarbons and combinations thereof. 
     
     
         25 . A catalyst formed from a precursor, wherein the precursor is formed by a process consisting essentially of:
 contacting, in a single reagent or mixture of reagents, a magnesium dialkoxide compound with a plurality of unblended compounds to thereby precipitate a solid catalyst precursor, wherein the first and second compounds are independently represented by the formula: A(O x R′X q   1 ) y (O x R″X p   2 ) z  wherein A is independently selected from titanium, silicon, aluminum, carbon, tin and germanium; X 1  and X 2  are optional and when one and/or the other are present, they are the same or different heteroatoms; R′ and R″ are independently selected from C 2 -C 8  which may be branched, linear, cyclic or aromatic; x is 0 or 1; and y+z is the valence of A; wherein the first and second compounds are contacted with the magnesium dialkoxide in the substantial absence of metal halide; and wherein the third compound is contacted last and is TiCl 4 .