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.

The invention relates to a process for the preparation of a propylene homopolymer or a propylene α-olefin random copolymer comprising the step of a) preparing a propylene homopolymer or a propylene α-olefin random copolymer, wherein the α-olefin is chosen from the group consisting of ethylene, and α-olefins having 4 to 10 carbon atoms, for example 1-butene or 1-hexene by contacting at least the propylene and optionally α-olefin, with a catalyst in a gas-phase reactor at a temperature T1 and a pressure P1, wherein T1 is chosen in the range from 75 to 90° C., for example in the range from 77 to 85° C., for example in the range from 78 to 83° C., wherein P1 is chosen in the range from 22 to 30 bar to prepare a propylene homopolymer (A′) or a propylene α-olefin random copolymer (A′).

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.

The invention relates to a process for preparing a solid support for a procatalyst suitable for preparing a catalyst composition for olefin polymerization, said process for preparing said solid support comprising reacting a compound R.sup.4.sub.zMgX.sup.4.sub.2-z with a silane compound Si(OR.sup.5).sub.4-n(R.sup.6).sub.n in a solvent and mixing the resulting mixture with a mixing device and at a certain mixing speed in order to give a solid support Mg(OR.sup.1).sub.xX.sup.1.sub.2-x said solid support obtained having an average particle size of at most 17 μm, preferably at most 16 or 14 μm, more preferably at most 12 μm. The invention further relates to a solid support, a process for preparing a procatalyst and said procatalyst as well as polyolefins obtained using said procatalyst.

A process for preparing a solid pre-catalyst component for use in olefinic polymerization includes dissolving a magnesium chloride in an alcohol and optionally adding water to form a first solution having a water content of about 0.5 mmol water per mol MgCl.sub.2 to about 100 mmol water per mol MgCl.sub.2; contacting the first solution with a first titanium compound to form the solid pre-catalyst component; and treating the solid pre-catalyst component with a hydrocarbon or halogenated hydrocarbon solvent, optionally containing a second titanium compound.

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 an alkoxy- or aryloxy silane compound, to give a solid support; Step C) optionally contacting the solid support obtained with at least one activating compound; and Step D) reacting the (activated) support with a halogen-containing Ti-compound as catalytic species, an activator and at least one internal electron donor in several sub steps wherein the internal donor is added in portions during at least two of said stages to obtain a 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 continuous production of a polyolefin, preferably polypropylene, in a horizontal stirred bed polymerization reactor by contacting one or more olefins, preferably propylene, with a catalyst system while stirring, said catalyst system comprising: * a procatalyst comprising i) titanium; ii) a magnesium-containing support, preferably a magnesium chloride-containing support, and iii) an internal electron donor; * optionally an external electron donor; and * a co-catalyst, being a alkyl aluminum catalyst having formula AlX.sub.nR.sub.3-n, wherein each X is independently a halide or a hydride and wherein n is 0, 1 or 2, preferably 0, and wherein R is an C1-C12 alkyl group, preferably ethyl, wherein the molar ratio of aluminum (Al) from the co-catalyst to titanium (Ti) from the procatalyst (Al/Ti) is at least 75. The present invention also relates to polyolefin prepared using said process and a shaped article comprising said polyolefin. The present invention moreover relates to the use of a titanium to aluminum ratio during the Ziegler-Natta polymerization of olefins in a horizontal stirred bed reactor to reduce the energy (power) consumption in view of a situation wherein the titanium to aluminum ratio is lower.

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.