Process for forming a Ziegler-Natta catalyst system having a controlled morphology

Abstract

A pre-catalyst is formed by reacting butylethylmagnesium with an alcohol to form a magnesium alkoxide compound, followed by contacting the magnesium alkoxide compound with a phosphorous compound to form a magnesium alkoxide phosphorous compound mixture. The magnesium alkoxide phosphorous compound mixture is subsequently reacted with TiCl 4 to form a MgCl 2 support. The MgCl 2 support is then contacted with an internal donor while being heated to form a first catalyst slurry, which is then contacted with TiCl 4 while being heated to form a second catalyst slurry. The second catalyst slurry is next contacted with TiCl 4 while being heated to form a third catalyst slurry, which is washed and dried, resulting in a highly active pre-catalyst with controlled morphology. The pre-catalyst may be combined with one or more co-catalysts and optionally one or more external electron donors to form an active catalyst system, which may be used for the polymerization of olefins.

1 - 31 . (canceled)  
   
   
       32 . A polymer produced by combining one or more olefin monomers under reaction conditions suitable for polymerization with a catalyst system having a pre-catalyst formed by a process comprising: 
 (a) combining a magnesium alkyl compound with an alcohol to form a magnesium alkoxide compound;    (b) combining the magnesium alkoxide compound with an phosphorous compound to form a mixture; and    (c) combining the mixture with a precipitating agent to form a magnesium chloride support.    
   
   
       33 . The polymer of  claim 32 , wherein the polymer is polypropylene having about 0.7 to about 7.0 wt. % xylene solubles.  
   
   
       34 . The polymer of  claim 32 , wherein the polymer particles consist essentially of agglomerated spheroids having a weight average particle size of about 150 to about 500 microns.  
   
   
       35 . The polymer of  claim 33 , wherein the polypropylene has a molecular weight distribution of about 6 to about 10.  
   
   
       36 . The polymer of  claim 35 , wherein the polypropylene has an isotacticity of about 94.0 to about 97.0 mol. %.  
   
   
       37 . The polymer of  claim 36 , wherein the polypropylene has less than about 1 wt. % fines.  
   
   
       38 . The polymer of  claim 37 , wherein the polypropylene has a weight average particle size (d 50 ) of about 150 to about 500.  
   
   
       39 . The polymer of  claim 38 , wherein the polypropylene has a span ((d 90 -d 10 )/d 50 ) is about 0.5 to about 3.0.  
   
   
       40 . The polymer of  claim 39 , wherein the polypropylene has a melt flow rate of about 2 to about 50 g/10 min.  
   
   
       41 . The polymer of  claim 40 , wherein the polypropylene has a bulk density of about 0.36 to about 0.43 g/cm 3 .  
   
   
       42 . Film, fiber, or an article of manufacture comprising the polymer of  claim 32.