Patent ID: 6852811

Claim:
A process for preparing an olefin polymerization catalyst comprising the steps of: A. calcining silica at a temperature of 30 to 1000° C. to form calcined silica, B. reacting the calcined silica with an agent selected from the group consisting of: i. Lewis acid alkylating agents, ii. silane or chlorosilane functionalizing agents, and iii. aluminum components selected from an alumoxane or an aluminum compound of the formula AIR 1 x′ R 2 y′ , wherein R 1 independently each occurrence is hydride or R, R 2 is hydride, R or OR, wherein R is a C 1 to C 10 hydrocarbyl group, x′ is 2 or 3, y′ is 0 or 1 and the sum of x′ and y′ is 3, to form a support precursor having a specified pore volume, C. applying to the support precursor a first solution in a compatible solvent of one of the following: (1) a complex of a metal of Group 3, 4, or the Lanthanide metals of the Periodic Table of the Elements or (2) a cocatalyst selected from the group consisting of non-polymeric, non-oligomeric complexes capable of activating the complex of (C)(1) for the polymerization of α-olefins and removing the compatible solvent of the first solution to form a supported procatalyst; D. applying to the supported procatalyst a second solution in a compatible solvent of the other of the complex or the cocatalyst of (C) to form a supported catalyst, wherein the second solution is provided in an amount such that 100 percent of the pore volume of the support precursor is not exceeded; and E. removing the compatible solvent of the second solution from the supported catalyst to form a recovered supported olefin polymerization catalyst.