High efficiency catalyst for polymerizing olefins

Claim 1

A catalytic reaction product of (A) a tetravalent titanium compound represented by the formula TiX n (OR) 4-n wherein X is a halogen, R is an alkyl or an aryl group having from 1 to 12 carbon atoms and n has a value of 0 to 4, or a trivalent titanium complex represented by the formula TiZ 3 (L) x wherein Z is halide, and L is an electron donating compound selected from water, alcohol, ether, ketone, amine or olefin, and x is a number from 1 to 6; (B) an anhydrous divalent nickel compound represented by the formula Ni(Q) n wherein Q is an anion selected from halide, hydroxide, carboxylate, carbonate, nitrate, sulfate, or mixtures thereof and n is two divided by the valence of Q; (C) an organomagnesium component selected from (1) an organomagnesium compound or (2) a complex of an organomagnesium compound and an organometallic compound in an amount sufficient to solubilize the organomagnesium compound in a hydrocarbon solvent, said organomagnesium compound and said complex being represented respectively by the following formulas MgR" 2 and MgR" 2 .xMR 1 wherein each R" is independently a hydrocarbyl group having from 1 to 20 carbon atoms, M is a metal selected from Al, Zn, Si, Sn, B and P, y is the number of hydrocarbyl groups and corresponds to the valencey of M and x is about 0.001 to 10 and (D) a halide source selected from (1) an active non-metallic halide, said non-metallic halide corresponding to the formula R'X wherein R' is hydrogen or a hydrocarbyl such that the hydrocarbyl halide is at least as active as sec-butyl chloride and does not poison the catalyst and X is halogen or (2) a metallic halide corresponding to the formula MR y-a X a wherein M is a metal of Group 1B, 3A or 4A of Mendeleev's Periodic Table of Elements, R is a monovalent hydrocarbyl radical, X is halogen, y is a number corresponding to the valence of M and a is a number of 1 to y; provided that the proportions of the foregoing components of said catalytic reaction product being such that the atomic ratio of Mg:Ti is from about 1:1 to about 2000:1, the atomic ratio of Al:Ti is from about 0.1:1 to about 2000:1, the atomic ratio of Ni:Ti is from about 0.01:1 to about 500:1, the atomic ratio of excess X:Al is from about 0.0005:1 to about 10:1; and further provided that when the organomagnesium component and/or the halide source provides insufficient quantities of aluminum, there is also present an aluminum compound represented by the formula AlRy'Xy" wherein R and X are as defined above and y' and y" each have a value of from zero to three with the sum of y' and y" being three.