Spheroidal polymerization catalyst, process for preparing, and use for ethylene polymerization

Claim 1

A catalytic process for producing ethylene polymers selected from the group consisting of ethylene homopolymers and copolymers with a Ti containing catalyst at a productivity of 24 50,000 pounds of polymer per pound of Ti under a pressure of 21 1000 psi in the gas phase said polymer being produced in granular spherical form having a particle size of from about 250 to about 2550 microns and having a density of 24 0.91 to 23 0.97 and melt flow ratio of 24 22 to 23 32 which comprises homopolymerizing or copolymerizing ethylene at a temperature of about 30° to 115° C. by contacting the monomer charge with spherical particles of an activated catalyst composition produced by (A) forming a spherical precursor composition of the formula: Mg.sub.m Ti.sub.1 (OR).sub.n X.sub.p [ED].sub.q [Filler].sub.r wherein R is a C 1 to C 14 aliphatic or aromatic hydrocarbon radical, or COR' wherein R' is a C 1 to C 14 aliphatic or aromatic hydrocarbon radical, X is Cl, Br, I, or mixtures thereof, ED is an electron donor compound, Filler is an inert filler compound, and, based on the total weight of said composition, m is ≧0.5 to ≦56, n is 0 or 1, p is ≧2 to ≦116, q is ≧2 to ≦85, and r has a value such that the percent filler is from about 10 to about 95 weight percent based on the total weight of said composition, by forming a slurry or solution of at least one magnesium compound and at least one titanium compound and at least one filler compound in at least one electron donor compound so as to thereby form a slurry or solution of said precursor composition in said electron donor compound and spray drying said slurry or solution by atomization to form spherical particles of said precursor composition which have a particle size of from about 10 to about 200 microns, said magnesium compound having the structure MgX 2 , said titanium compound having the structure Ti(OR) a X b wherein a is 0, 1 or 2, b is 1 to 4 inclusive and a+b=3 or 4, said electron donor compound being a liquid organic compound in which said magnesium compound and said titanium compound are soluble and which is selected from the group consisting of alkyl esters of aliphtic and aromatic carboxylic acids, aliphatic ethers, cyclic ethers and aliphatic ketones and, (B) completely activating said precursor composition with 10 to 500 mols of activator compound per mol of Ti in said precursor composition, said activator compound having the formula Al(R").sub.c X'.sub.d H.sub.e wherein X' is Cl or OR'", R" and R'" are the same or different, and are C 1 to C 14 saturated hydrocarbon radicals, d is 0 to 1.5, e is 1 or 0 and c+d+e=3, said activating being conducted after the recovery of said particles of said precursor composition.