Chisso Corporation

The Institute of Physical and Chemical Research

Shinya Miya

Masato Harada

Hiroshi Yamazaki

Takaya Mise

Masami Tachibana

Sadahiko Yamada

Makoto Iijima

Takashi Yoshimura

Yuuji Karasawa

A process for producing a catalyst component for olefin polymerization is provided, which process comprises spraying a solution of a magnesium compound e.g. MgCl.sub.2 and an alcohol such as MgCl.sub.2. nROH (wherein R is 1-10 C alkyl and n is 3-6) into a cooled spray column to obtain a spherical solid component (carrier) without any substantial vaporization of the alcohol, followed by partly drying the component for a time till a specified ratio of the alcohol/MgCl.sub.2 is attained, and then subjecting the resulting component to treatment with a titanium halide and an electron-donating component, the resulting component having a large particle diameter, without any dispersion of the solvent content in the component particles and also without any breakage of the particles when subjected to treatment with the titanium halides.

Process for producing a catalyst for olefin polymerization

A novel transition-metal compound having a bis-substituted cyclopentadienyl ligand of bridged structure (I) and a novel mixture of the compound (I) with an aluminoxane (B), each useful as catalyst component(s) for stereoregular olefin polymerization are provided, which compound (I) is expressed by the formula ##STR1## wherein M is Zr or Hf; Y is Si or Ge; R.sup.1.sub.n -C.sub.5 H.sub.4-n and R.sup.1.sub.q -C.sub.5 H.sub.4-q each represent an unsubstituted or substituted cyclopentadienyl group; n and q each represent an integer of 0 to 4, but cases of n=q=0 and n=q=4 are excluded; R.sup.1 s may be same or different and each represent H, silyl or hydrocarbon radical; R.sup.2 s may be same or different and represent H or hydrocarbon radical; and Xs may be same or different and represent H, halogen or hydrocarbon radical; and which aluminoxane is expressed by the formula (II) or the formula (III) ##STR2## wherein m represents an integer of 4 to 30 and R.sup.3 represents a hydrocarbon radical.

Transition-metal compound having a bis-substituted-cyclopentadienyl

Bis(di-, tri- or tetra-substituted-cyclopentadienyl)zirconium dihalides represented by the following general formula [I] are provided, ##STR1## (wherein R.sup.1 denotes a substituent group on the cyclopentadienyl ring which is an alkyl radical of 1 to 5 carbon atoms; R.sub.2.sup.1 --C.sub.5 H.sub.3 stands for a di-substituted cyclopentadienyl radical; and X is a halogen atom). This compound, when combined with an aluminoxane repesented by the following general formula [VII], gives a high-activity catalyst for the synthesis of polyolefins, ##STR2## (wherein m is an integer of 4 to 20; and R.sup.2 denotes a hydrocarbyl radical).

Bis(di-, tri- or tetra-substituted-cyclopentadienyl)-zirconium dihalides

A solid catalyst component for olefin polymerization having a high polymerization activity and affording a highly stereoregular polymer having a good particulate form, and a process for producing the same are provided, which component indispensably contains Mg, Ti, Al, halogen and alkoxy group; has two absorption peaks (absorbances A.sub.1 and A.sub.2) at specified wavenumbers within a specified region of spectra according to infrared spectrophotometry, A.sub.1 /A.sub.2 and A.sub.1 /A.sub.3 (A.sub.3 : an absorbance at a specified wavenumber) being each in a specified range; and has X-ray diffraction spectra distinctive from those of Mg halide or its complex with electron donor, and which process consists of step I of dissolving (a) anhydrous Mg dihalide, (b) a specified orthotitanic or polytitanic acid ester and (c) a specified alcohol in an inert hydrocarbon solvent to prepare component A; step II of mixing and reacting component A with component B consisting of (d) a specified organic acid ester, (e) a specified Al halide and (f) a specified Si halide to prepare solid product (I); and step III of reacting solid product (I) with component C consisting of (g) a specified Ti halide and/or (h) a specified vanadyl or vanadium halide to obtain solid product (II) as the objective catalyst component.

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Ichiharashi, Japan

Shinya Miya