The present invention relates to a solid Ziegler-Natta catalyst component for olefin polymerization containing an organosilicon element in combination with one or more internal electron donors. The catalyst components, according to the present invention, are able to produce polypropylene polymers with higher stereo-regularity. The present invention also provides a phthalate-free catalyst system capable of producing polypropylene with an isotacticity that is equal to or higher than catalyst systems containing phthalate derivatives.

A process of preparing a solid catalyst component for the production of polypropylene includes a) dissolving a halide-containing magnesium compound in a mixture, the mixture including an epoxy compound, an organic phosphorus compound, and a hydrocarbon solvent to form a homogenous solution; b) treating the homogenous solution with an organosilicon compound during or after the dissolving step; c) treating the homogenous solution with a first titanium compound in the presence of a first non-phthalate electron donor, and an organosilicon compound, to form a solid precipitate; and d) treating the solid precipitate with a second titanium compound in the presence of a second non-phthalate electron donor to form the solid catalyst component, where the process is free of carboxylic acids and anhydrides.

A process for preparing a catalyst component, including: contacting a compound R.sup.9.sub.zMgX.sub.2-z wherein R.sup.9 is aromatic, aliphatic or cyclo-aliphatic group containing up to 20 carbon atoms, X is a halide, and z is larger than 0 and smaller than 2, with an alkoxy- or aryloxy-containing silane compound to give a first intermediate reaction product; contacting the first intermediate reaction product with at least one activating compound selected electron donors, compounds of formula M(OR.sup.10).sub.v-w(OR.sup.11).sub.w, wherein M is Ti, Zr, Hf, Al or Si, and M(OR.sup.10).sub.v-w(R.sup.11).sub.w wherein M is Si, each R.sup.10 and R.sup.11, independently, represent an alkyl, alkenyl or aryl group, v is the valency of M, v is 3 or 4, and w is less than v, to give a second intermediate reaction product; and contacting the second intermediate reaction product with a halogen-containing Ti-compound, a monoester as activating agent, and a 1,3-diether as an internal electron donor.

The invention relates to Process for the preparation of a polypropylene composition comprising a propylene-based polymer which is a propylene homopolymer or propylene-ethylene copolymer having an ethylene content of less than 1.0 wt % based on the propylene-ethylene copolymer, wherein the polypropylene composition has a melt flow rate (MFR) in the range from 0.50 to 110 dg/min, wherein the melt flow rate is determined using 1501133-1:2011 using 2.16 kg at 230 C., wherein the process comprises the step of polymerizing propylene and optional ethylene comonomers in the presence of a catalyst in a gas phase to obtain the propylene-based polymer, wherein said catalyst comprises a procatalyst, a cocatalyst and optionally an external electron donor, wherein the procatalyst is obtainable by a process comprising the steps of: contacting a magnesium-containing support with a halogen containing titanium compound, and an internal electron donor according to Formula (I) wherein R.sup.1 is a secondary alkyl group and R.sup.2 is a non-secondary alkyl group having at least 5 carbon atoms, preferably R is a non-secondary alkyl group being branched at the 3-position or further positions; said procatalyst is prepared according to the following steps: i) contacting a compound R4zMgX 4.sub.2-z with an alkoxy- or aryloxy-containing silane compound to give a first intermediate reaction product, being a solid Mg(OR.sup.a) X.sup.1.sub.2-x-wherein: R.sup.a is a linear, branched or cyclic hydrocarbyl group independently selected from alkyl, alkenyl, aryl, aralkyl, alkoxycarbonyl or alkylaryl groups, and one or more combinations thereof; wherein said hydrocarbyl group may be substituted or unsubstituted, may contain one or more heteroatoms and preferably has from 1 to 20 carbon atoms; wherein R.sup.4 is a linear, branched or cyclic hydrocarbyl group independently selected from alkyl, alkenyl, aryl, aralkyl, alkoxycarbonyl or alkylaryl groups, and one or more combinations thereof; wherein said hydrocarbyl group may be substituted or unsubstituted, may contain one or more heteroatoms and preferably has from 1 to 20 carbon atoms, preferably R.sup.4 is butyl; wherein X.sup.4 and X.sup.1 are each independently selected from the group of consisting of fluoride (F), chloride (Cl), bromide (Br) or iodide (I), preferably chloride; z is in a range of larger than 0 and smaller than 2, being 0<z<2, x is an N integer between 0 and 2; ii) optionally contacting the solid Mg(OR.sup.a)xX1.sub.2-x obtained in step i) with at least one activating compound selected from the group formed by activating electron donors and metal alkoxide compounds of formula M.sup.1(OR.sup.b).sub.v-w(OR.sup

The invention relates to Process for the preparation of a polypropylene composition comprising a propylene-based polymer which is a propylene homopolymer or propylene-ethylene copolymer having an ethylene content of less than 1.0 wt % based on the propylene-ethylene copolymer, wherein the polypropylene composition has a melt flow rate (MFR) in the range from 0.50 to 110 dg/min, wherein the melt flow rate is determined using 1501133-1:2011 using 2.16 kg at 230 C., wherein the process comprises the step of polymerizing propylene and optional ethylene comonomers in the presence of a catalyst in a gas phase to obtain the propylene-based polymer, wherein said catalyst comprises a procatalyst, a cocatalyst and optionally an external electron donor, wherein the procatalyst is obtainable by a process comprising the steps of: contacting a magnesium-containing support with a halogen containing titanium compound, and an internal electron donor according to Formula (I) wherein R.sup.1 is a secondary alkyl group and R.sup.2 is a non-secondary alkyl group having at least 5 carbon atoms, preferably R is a non-secondary alkyl group being branched at the 3-position or further positions; said procatalyst is prepared according to the following steps: i) contacting a compound R4zMgX 4.sub.2-z with an alkoxy- or aryloxy-containing silane compound to give a first intermediate reaction product, being a solid Mg(OR.sup.a) X.sup.1.sub.2-x-wherein: R.sup.a is a linear, branched or cyclic hydrocarbyl group independently selected from alkyl, alkenyl, aryl, aralkyl, alkoxycarbonyl or alkylaryl groups, and one or more combinations thereof; wherein said hydrocarbyl group may be substituted or unsubstituted, may contain one or more heteroatoms and preferably has from 1 to 20 carbon atoms; wherein R.sup.4 is a linear, branched or cyclic hydrocarbyl group independently selected from alkyl, alkenyl, aryl, aralkyl, alkoxycarbonyl or alkylaryl groups, and one or more combinations thereof; wherein said hydrocarbyl group may be substituted or unsubstituted, may contain one or more heteroatoms and preferably has from 1 to 20 carbon atoms, preferably R.sup.4 is butyl; wherein X.sup.4 and X.sup.1 are each independently selected from the group of consisting of fluoride (F), chloride (Cl), bromide (Br) or iodide (I), preferably chloride; z is in a range of larger than 0 and smaller than 2, being 0<z<2, x is an N integer between 0 and 2; ii) optionally contacting the solid Mg(OR.sup.a)xX1.sub.2-x obtained in step i) with at least one activating compound selected from the group formed by activating electron donors and metal alkoxide compounds of formula M.sup.1(OR.sup.b).sub.v-w(OR.sup

The present invention relates to a process for the preparation of a procatalyst suitable for preparing a catalyst composition for olefin polymerization, said process comprising the steps of: Step A) providing or preparing a Grignard compound; Step B) contacting the Grignard compound with a silane compound to give a solid support; Step C) activating said solid support, comprising two sub steps: Step C1) contacting the solid support obtained in step B) with at least one first activating compound and a second activating compound; and Step C2) a second activation step by contacting the partly activated solid support obtained in step C1) with an activating electron donor; to obtain an activated solid support; Step D) reacting the activated solid support obtained in step C) with a halogen-containing Ti compound, optionally an activator and at least one internal electron donor in several sub steps to obtain said procatalyst. The invention moreover relates to a procatalyst, a catalytic system comprising said procatalyst and to a process to prepare polyolefins using said catalyst system and the polyolefins obtained therewith.

The present invention relates to a process for the preparation of a procatalyst suitable for preparing a catalyst composition for olefin polymerization, said process comprising the steps of: Step A) providing or preparing a Grignard compound; Step B) contacting the Grignard compound with a silane compound to give a solid support; Step C) activating said solid support, comprising two sub steps: Step C1) contacting the solid support obtained in step B) with at least one first activating compound and a second activating compound; and Step C2) a second activation step by contacting the partly activated solid support obtained in step C1) with an activating electron donor; to obtain an activated solid support; Step D) reacting the activated solid support obtained in step C) with a halogen-containing Ti compound, optionally an activator and at least one internal electron donor in several sub steps to obtain said procatalyst. The invention moreover relates to a procatalyst, a catalytic system comprising said procatalyst and to a process to prepare polyolefins using said catalyst system and the polyolefins obtained therewith.

A solid catalyst component for the polymerization of olefins, made from or containing Ti, Mg and an internal donor selected from 1,3-diethers, wherein the solid catalyst component, has (i) an average particle size D50 ranging from 55 to 80 m and (ii) a surface area (SA), determined with the BET method, such that the value of the formula SAD50/100 is higher than 60.

A solid catalyst component for the polymerization of olefins, made from or containing Ti, Mg and an internal donor selected from 1,3-diethers, wherein the solid catalyst component, has (i) an average particle size D50 ranging from 55 to 80 m and (ii) a surface area (SA), determined with the BET method, such that the value of the formula SAD50/100 is higher than 60.