Preparation of precipitated zn pp catalysts with internal pore structure using nanoparticles

Abstract

Process for the preparation of a catalyst being in the form of solid particles comprising the steps of preparing a solution of a complex of a metal which is selected from one of the groups 1 to 3 of the periodic table (IUPAC) and an electron donor by reacting a compound of said metal with said electron donor in an organic liquid reaction medium; adding to said solution solid material obtaining a suspension, said solid material does not comprise catalytically active sites, has a specific surface area below 500 m 2 /g, and has a mean particle size below 200 nm; combining said suspension at a temperature of at least 50° C. with at least one transition metal compound resulting in a precipitation of said catalyst being in the form of a solid particle, wherein said transition metal compound is selected from one of the groups 4 to 10 of the periodic table (IUPAC) or a compound of actinide or lanthanide; and optionally separating said catalyst; said catalyst being in the form of solid particles, which have a specific surface area of less than 20 m 2 /g, and contain said solid material.

1 - 8 . (canceled) 
     
     
         9 . Catalyst in form of solid particles, wherein the particles
 (a) have a specific surface area of less than 20 m 2 /g,   (b) have a particle size distribution of a SPAN value of at least 2.0,   (c) optionally are free of any precipitating agents,   (d) comprise a transition metal compound which is selected from one of the groups 4 to 10 of the periodic table (IUPAC) or a compound of actinide or lanthanide,   (e) comprise a metal compound which is selected from one of the groups 1 to 3 of the periodic table (IUPAC), and   (f) comprise solid material, wherein the solid material
 (i) does not comprise catalytically active sites, 
 (ii) has a specific surface area below 500 m 2 /g, and 
 (iii) has a mean particle size below 200 nm. 
   
     
     
         10 . Catalyst according to  claim 9 , wherein the solid particles are precipitated solid particles. 
     
     
         11 . Catalyst according to  claim 9 , wherein the solid material does not comprise
 (a) transition metal compounds which are selected from one of the groups 4 to 10 of the periodic table (IUPAC) and   (b) compounds of actinide or lanthanide.   
     
     
         12 . Catalyst according to  claim 9 , wherein the solid material is selected from the group consisting of inorganic materials, organic materials and any combination thereof. 
     
     
         13 . Catalyst according to  claim 9 , wherein the solid material has
 (a) mean particle size of not more than 90 nm and/or   (b) a specific surface area of below 450 m 2 /g.   
     
     
         14 . Catalyst according to  claim 9 , wherein the solid particle have:
 (a) a specific surface area of less than 10 m 2 /g and/or   (b) a pore volume of less than 1.0 ml/g and/or   (c) a mean particle size below 80 μm.   
     
     
         15 . Catalyst according to  claim 9 , wherein the solid particles comprise a compound of formula (I):
   AlR 3-n X n   (I)
   wherein   R stands for a straight chain or branched alkyl or alkoxy group having 1 to 20 carbon atoms,   X stands for halogen, and   n stands for 0, 1, 2 or 3.   
     
     
         16 . (canceled) 
     
     
         17 . Catalyst as defined in  claim 9 , being used in a polymerization process of polypropylene. 
     
     
         18 . (canceled)