Method of producing metal halide catalyst

摘要

A polymerization catalyst is formed by combining a metal halide compound, a solvent, an effective amount of water to reduce fines and increase particle size, and a transition metal compound to form a first catalyst component and mixing the first catalyst component with a precipitating agent. After mixing the first catalyst component and the precipitating agent, the mixture can be heated to a temperature higher than the mixing temperature to reduce polymer fines. In the alternative prepolymer can be deposited on the catalyst(s) in an amount effective to reduce polymer fines. Optionally the catalyst can be treated with a halide ion exchanging source. The catalyst can also be combined with an organometallic cocatalyst.