The present invention relates to Ziegler-Natta catalyst components for olefin polymerization employing specific carbonate compounds as an element of solid catalyst composition in conjunction with at least one or more internal donor compounds, for producing polyolefins, particularly polypropylene and ethylene-propylene block co-polymer, which exhibits substantially high rubber content with higher stereo-regularity and hydrogen response.

Methods of preparing a polymerization catalyst component is provided, in which a magnesium component, a Lewis acid solubilizing component, a titanium compound, optionally a transition metal compound different than the titanium compound, and typically an inert filler are combined in a slurrying agent and spray-dried to produce a catalyst precursor in the form of a substantially spherical and porous solid particle. The methods and catalysts of this disclosure can provide ethylene homopolymer and copolymer resins having a high molecular weight tail and a broadened molecular weight distribution as compared to more traditional Ziegler-Natta catalysts.

Methods of preparing a polymerization catalyst component is provided, in which a magnesium component, a Lewis acid solubilizing component, a titanium compound, optionally a transition metal compound different than the titanium compound, and typically an inert filler are combined in a slurrying agent and spray-dried to produce a catalyst precursor in the form of a substantially spherical and porous solid particle. The methods and catalysts of this disclosure can provide ethylene homopolymer and copolymer resins having a high molecular weight tail and a broadened molecular weight distribution as compared to more traditional Ziegler-Natta catalysts.

Provided is a particle drying method capable of sufficiently removing the volatile component and down-regulating the increase of the viscosity of the particles after the removal of the volatile component. There is provided a method for producing heterophasic propylene polymerization material particles, the method including: (1) performing monomer polymerization in the presence of a catalyst including a solid catalyst component so as to obtain a component I; (2) performing monomer polymerization in the presence of the component I so as to obtain the component II, so that particles including a volatile component are produced; and (3) causing the particles to contact with an inert gas-containing stream so as to remove the volatile component from the particles.

Provided is a particle drying method capable of sufficiently removing the volatile component and down-regulating the increase of the viscosity of the particles after the removal of the volatile component. There is provided a method for producing heterophasic propylene polymerization material particles, the method including: (1) performing monomer polymerization in the presence of a catalyst including a solid catalyst component so as to obtain a component I; (2) performing monomer polymerization in the presence of the component I so as to obtain the component II, so that particles including a volatile component are produced; and (3) causing the particles to contact with an inert gas-containing stream so as to remove the volatile component from the particles.

A procatalyst for polymerization of olefins, based on a magnesium compound of the formula MgRR wherein R is an alkoxide or aryloxide group and R is an alkoxide or aryloxide group or halogen that has been reacted with a tetravalent titanium halide, an activator being a monoester and an internal donor of formula B:

##STR00001##

as described herein. Also described is a polymerization catalyst system comprising the procatalyst, a co-catalyst and optionally an external electron donor; a process of making a polyolefin by contacting an olefin with the catalyst system; a polyolefinobtained by or obtainable by the process; and a polyolefin, preferably a polypropylene, having a molecular weight distribution of between 3 and 15, a molecular weight (M.sub.w) of between 200,000 to 1,000,000 g/mol, a melting temperature of more than 145 C., a value for the xylene solubles of less than 4 wt. % and a shaped article therefrom.

A procatalyst for polymerization of olefins, based on a magnesium compound of the formula MgRR wherein R is an alkoxide or aryloxide group and R is an alkoxide or aryloxide group or halogen that has been reacted with a tetravalent titanium halide, an activator being a monoester and an internal donor of formula B:

##STR00001##

as described herein. Also described is a polymerization catalyst system comprising the procatalyst, a co-catalyst and optionally an external electron donor; a process of making a polyolefin by contacting an olefin with the catalyst system; a polyolefinobtained by or obtainable by the process; and a polyolefin, preferably a polypropylene, having a molecular weight distribution of between 3 and 15, a molecular weight (M.sub.w) of between 200,000 to 1,000,000 g/mol, a melting temperature of more than 145 C., a value for the xylene solubles of less than 4 wt. % and a shaped article therefrom.

A procatalyst for polymerization of olefins, which procatalyst is based on a magnesium compound of the formula MgRR wherein R is an alkoxide or aryloxide group and R is an alkoxide or aryloxide group or halogen, an activator being a monoester and an internal donor represented by a compound according to formula A: ##STR00001##
as described herein. Also described is a polymerization catalyst system comprising the procatalyst, a co-catalyst and optionally an external electron donor; a process of making a polyolefin, by contacting an olefin with the catalyst system; a polyolefin, obtained by or obtainable by the process; and a polyolefin, having a molecular weight distribution of between 4 and 15, a molecular weight (M.sub.w) of between 300,000 to 1,500,000 g/mol, a melting temperature of more than 150 C., a value for the xylene solubles of less than 4 wt. % and a shaped article therefrom.

A procatalyst for polymerization of olefins, which procatalyst is based on a magnesium compound of the formula MgRR wherein R is an alkoxide or aryloxide group and R is an alkoxide or aryloxide group or halogen, an activator being a monoester and an internal donor represented by a compound according to formula A: ##STR00001##
as described herein. Also described is a polymerization catalyst system comprising the procatalyst, a co-catalyst and optionally an external electron donor; a process of making a polyolefin, by contacting an olefin with the catalyst system; a polyolefin, obtained by or obtainable by the process; and a polyolefin, having a molecular weight distribution of between 4 and 15, a molecular weight (M.sub.w) of between 300,000 to 1,500,000 g/mol, a melting temperature of more than 150 C., a value for the xylene solubles of less than 4 wt. % and a shaped article therefrom.

The present invention relates to a process for the continuous preparation of a polyolefin in a reactor from one or more -olefin monomers of which at least one is ethylene or propylene, wherein the reactor comprises a fluidized bed, an expanded section located at or near the top of the reactor, a distribution plate located at the lower part of the reactor and an inlet for a recycle stream located under the distribution plate, wherein the process comprisesfeeding a polymerization catalyst to the fluidized bed in the area above the distribution platefeeding the one or more -olefin monomers to the reactorwithdrawing the polyolefin from the reactorcirculating fluids from the top of the reactor to the bottom of the reactor, wherein the circulating fluids are cooled using a heat exchanger, resulting in a cooled recycle stream comprising liquid, and wherein the cooled recycle stream is introduced into the reactor using the inlet for the recycle stream wherein a stream comprising a thermal run away reducing agent (TRRA-containing stream) is introduced into the expanded section during at least part of the polymerization process, wherein said TRRA-containing stream is brought into contact with at least part of the interior surface of the expanded section.