Process for the preparation of an unsupported, solid olefin polymerisation catalyst and use in polymerisation of olefins

Abstract

Improved process for the preparation of an unsupported, heterogeneous olefin polymerization catalyst, comprising an organometallic compound of a transition metal of Group 3 to 10 of the Periodic Table (IUPAC) or of an actinide or lanthanide in the form of solid particles comprising the steps of a) preparing a solution of an aluminoxane and an ionic complex M-X, M being an alkali or earth alkali metal and X being a halide or pseudo halide, in a molar ratio of Al of the aluminoxane to M of the ionic complex between 80:1 and 300:1, b) mixing said solution with an organometallic compound of a transition metal of Group 3 to 10 of the Periodic Table (IUPAC) or of an actinide or lanthanide in a molar ratio of M of the ionic complex to the transition metal of the organometallic compound between 1:1 and 4:1, yielding a second solution, c) dispersing said second solution obtained in step b) in a solvent immiscible therewith to form an emulsion in which said second solution of step b) forms the dispersed phase in the form of droplets and the solvent immiscible with said solution forms the continuous phase, d) solidifying said dispersed phase to convert said droplets to solid particles and optionally recovering aid particles to obtain said catalyst, the catalysts itself and its use for olefin polymerization.