Formation of a Ziegler-Natta catalyst

1. A process of forming a Ziegler Natta catalyst comprising:

reacting a reaction mixture comprising magnesium ethoxide (Mg(OEt) 2 ), triethylaluminum (TEAl), and 2-ethylhexanol (2-EHOH) to form magnesium 2-ethyl hexyl alkoxide (Mg(2-EHO) 2 );

contacting Mg(2-EHO) 2 in hexane with a first agent to form a reaction product “A” wherein the first agent the first agent is represented by the formula:

ClA(O x R 4 ) y ;

wherein A is selected from titanium, silicon, aluminum, carbon, tin and germanium; R 4 is selected from C1 to C10 alkyls; x is 0 or 1; and y is the valence of A minus 1;

contacting the reaction product “A” with a second agent to form a reaction product “B”, wherein the second agent includes a transition metal and a halogen;

contacting the reaction product “B” with a third agent to form a reaction product “C”, wherein the third agent includes a first metal halide;

contacting the reaction product “C” with a fourth agent to form a reaction product “D”, wherein the fourth agent includes a second metal halide; and

contacting the reaction product “D” with a fifth agent to form a Ziegler-Natta catalyst, wherein the fifth agent includes an organoaluminum compound.

2. The process of claim 1 , wherein the reaction mixture further comprises hexane.

3. The process of claim 1 , wherein the step of reacting a reaction mixture further comprises:

heating the mixture.

4. The process of claim 3 , wherein the reaction mixture is heated at a hexane reflux temperature.

5. The process of claim 1 , wherein the TEAl is present in the reaction mixture in a molar equivalent of between 0.25 and 1 relative to the Mg(OEt) 2 , and the 2-EHOH is present in the reaction mixture in a molar equivalent of between 2.75 and 3.5 relative to the Mg(OEt) 2 .

6. The process of claim 1 , wherein the reaction mixture does not include butylethylmagnesium (BEM).

7. A method of forming a polyolefin comprising:

contacting the Ziegler-Natta catalyst of claim 1 with an olefin monomer to form a polyolefin.

8. A process of forming a Ziegler Natta catalyst comprising:

reacting a reaction mixture comprising magnesium ethoxide (Mg(OEt) 2 ), triethylaluminum (TEAl), 2-ethylhexanol (2-EHOH), and titanium 2-ethyl hexyl alkoxide (Ti(2-EHO 4 )) to form solution A;

contacting solution A in hexane with a first agent to form a reaction product “A”, wherein the first agent the first agent is represented by the formula:

ClA(O x R 4 ) y ;

wherein A is selected from titanium, silicon, aluminum, carbon, tin and germanium; R 4 is selected from C 1 to C 10 alkyls; x is 0 or 1; and y is the valence of A minus 1;

contacting the reaction product “A” with a second agent to form a reaction product “B”, wherein the second agent includes a transition metal and a halogen;

contacting the reaction product “B” with a third agent to form a reaction product “C”, wherein the third agent includes a first metal halide;

contacting the reaction product “C” with a fourth agent to form a reaction product “D”, wherein the fourth agent includes a second metal halide; and

contacting the reaction product “D” with a fifth agent to form a Ziegler-Natta catalyst, wherein the fifth agent includes an organoaluminum compound.

9. The process of claim 8 , wherein solution A does not include HCl.

10. The process of claim 8 , wherein the reaction mixture does not include butylethylmagnesium (BEM).

11. The process of claim 8 , wherein the TEAl is present in the reaction mixture in a molar equivalent of between 0.25 and 1 relative to the Mg(OEt) 2 , and the 2-EHOH is present in the reaction mixture in a molar equivalent of between 0.75 and 2 relative to the Mg(OEt) 2 .

12. The process of claim 8 , wherein the reaction mixture further comprises hexane.

13. The process of claim 12 , wherein the step of reacting a reaction mixture further comprises:

heating the mixture.

14. The process of claim 13 , wherein the reaction mixture is heated at a hexane reflux temperature.

15. A method of forming a polyolefin comprising:

contacting the Ziegler-Natta catalyst of claim 8 with an olefin monomer to form a polyolefin.

16. A process of forming a Ziegler-Natta catalyst comprising:

reacting a reaction mixture comprising magnesium ethoxide (Mg(OEt) 2 ), triethylaluminum (TEAl), and 2-ethylhexanol (2-EHOH) to form magnesium 2-ethyl hexyl alkoxide (Mg(2-EHO) 2 );

contacting Mg(2-EHO) 2 in hexane with a chlorinated compound, to form a reaction product “A,” wherein the chlorinated compound is represented by the formula:

ClA(O x R 4 ) y ;

wherein A is selected from titanium, silicon, aluminum, carbon, tin and germanium; R 4 is selected from C 1 to C 10 alkyls; x is 0 or 1; and y is the valence of A minus 1;

contacting the reaction product “A” with a titanium halide or titanium oxide to form a reaction product “B”;

contacting the reaction product “B” with a metal halide to form a reaction product “C”;

contacting the reaction product “C” with a metal halide to form a reaction product “D”; and

contacting the reaction product “D” with an organoaluminum compound to form a Ziegler-Natta catalyst.

17. A process of forming a Ziegler Natta catalyst comprising:

reacting a reaction mixture comprising magnesium ethoxide (Mg(OEt) 2 ), triethylaluminum (TEAl), 2-ethylhexanol (2-EHOH), and titanium 2-ethyl hexyl alkoxide (Ti(2-EHO 4 )) to form solution A;

contacting solution A in hexane with a chlorinated compound, to form a reaction product “A,” wherein the chlorinated compound is represented by the formula:

ClA(O x R 4 ) y ;

wherein A is selected from titanium, silicon, aluminum, carbon, tin and germanium; R 4 is selected from C 1 to C 10 alkyls; x is 0 or 1; and y is the valence of A minus 1;

contacting the reaction product “A” with a titanium halide or titanium oxide to form a reaction product “B”;

contacting the reaction product “B” with a metal halide to form a reaction product “C”;

contacting the reaction product “C” with a metal halide to form a reaction product “D”; and

contacting the reaction product “D” with an organoaluminum compound to form a Ziegler-Natta catalyst.