Process for producing polypropylene film

1. Process for producing a polymer film, comprising polymerizing at least one monomer comprising propylene in the presence of a Ziegler-Natta catalyst to produce a polymer comprising propylene units and forming the polymer into a film, wherein the Ziegler-Natta catalyst comprises an olefin polymerization catalyst comprising particles of size within a predetermined range, the olefin polymerization catalyst being obtained by preparing a solution of a complex of a Gp IIa metal and an electron donor by reacting a compound of said metal with said electron donor or a precursor thereof in an organic liquid reaction medium; reacting said complex in solution with at least one compound of a transition metal

a) to produce an emulsion comprising a dispersed phase containing more than 50 mol % of the Gp IIa metal in said complex;

maintaining the particles of said dispersed phase within an average size range 10 to 200 μm by agitation in the presence of an emulsion stabilizer and solidifying said particles; and

recovering, washing and drying said particles to obtain said catalyst component or

b) to produce a first oil phase which contains more than 50 mol % of the Gp IIa metal in said complex and a second oil phase immiscible therewith, the oil of the first oil phase being denser than the oil of the second oil phase;

sorbing said denser oil on a carrier having an average particle size of 10 to 200 μm and a pore volume of 0.5 to 4 ml/g;

solidifying said sorbed oil contained by said carrier;

recovering, washing and drying the carrier to obtain said catalyst component.

2. Process according to claim 1 , wherein the catalyst component is obtained by

preparing a solution of magnesium complex by reacting an alkoxy magnesium compound and an electron donor or precursor thereof in a C 6 -C 10 aromatic liquid reaction medium; reacting said magnesium complex with a compound of at least one IV valent Gp IVB metal at a temperature greater than 10° C. and less than 60° C., to produce an emulsion of a denser, TiCl 4 /toluene-insoluble, oil dispersed phase having Gp IVB metal/Mg mol ratio 0.1 to 10 in an oil disperse phase having Gp IVB metal/Mg mol ratio 10 to 100; maintaining the particles of said dispersed phase within the size range 10 to 200 μm by agitation in the presence of an emulsion stabilizer while heating the emulsion to solidify said particles; and recovering, washing and drying said particles to obtain said catalyst component.

3. Process according to claim 2 , wherein a turbulence minimizing agent is added into the reaction mixture before solidifying the particles of the dispersed phase, said turbulence minimizing agent being inert and soluble in the reaction mixture under the reaction conditions.

4. Process according to claim 1 , wherein the catalyst component is obtained by

preparing a solution of magnesium complex by reacting an alkoxy magnesium compound and an electron donor or precursor thereof in a C 6 -C 10 aromatic liquid reaction medium; reacting said magnesium complex with a compound of at least one IV valent Gp IVB metal at a temperature greater than 10° C. and less than 60° C., to produce a denser, TiCl 4 /toluene-insoluble, oil dispersed phase having Gp IVB metal/Mg mol ratio 0.1 to 10 and an oil immiscible therein having Gp IVB metal/Mg mol ratio 10 to 100; preferentially sorbing said denser oil on a carrier having an average particle size of 10 to 200 μm and a pore volume of 0.5 to 4 ml/g, heating the carrier containing said sorbed oil to solidify said sorbed oil, and recovering, washing and drying the carrier to obtain said catalyst component.

5. Process according to claim 1 , wherein the at least one monomer consists essentially of propylene.

6. Process according to claim 1 , wherein the at least one monomer comprises propylene and at least one member of the group consisting of ethylene and C 4 -C 10 α-olefins.