Catalyst components for propylene polymerization

1. A solid catalyst component for olefin polymerization, the solid catalyst component comprising:

a reaction product of a halide-containing magnesium compound with an epoxy compound;

an organic phosphorus compound;

a titanium compound;

an organosilicon compound;

an internal electron donor comprising a compound is represented by one of the following formulas:

wherein:

each of R 1 -R 14 and R 21 -R 34 are independently H, F, Cl, Br, I, alkyl, cycloalkyl, cycloalkylalkyl, aryl, aralkyl, heterocyclyl, heterocyclylalkyl, heteroaryl, or heteroarylalkyl; and

q is an integer from 0 to 12; and

wherein the solid catalyst component is free of side reaction products between a carboxylic acid or an anhydride thereof and a magnesium compound or a titanium compound, and wherein the solid catalyst component has a particle size from about 5 microns to about 70 microns (on a 50% by volume basis).

2. The solid catalyst component of claim 1 , further containing an aluminum compound.

3. The solid catalyst component of claim 1 , wherein the solid catalyst component has a BET surface area of from about 100 m 2 /g to about 500 m 2 /g.

4. The solid catalyst component of claim 1 , wherein the solid catalyst component does not include any side reaction products between an organic acid and a magnesium compound or a titanium compound.

5. The solid catalyst component of claim 1 , wherein the organic phosphorus compound comprises a phosphate acid ester.

6. A catalyst system containing the solid catalyst component of claim 1 in combination with an organoaluminum compound and at least one selectivity control agent.

7. The catalyst system of in claim 6 , further comprising an activity limiting agent.

8. The catalyst system of in claim 6 , wherein the selectivity control agent comprises dimethyldimethoxysilane, n-propyltrimethoxysilane, methylcyclohexyldimethoxysilane, diisopropyldimethoxysilane, n-propyltriethoxysilane, bis(perhydroisoquinolino) dimethoxysilane, 2,2,6,6-tetramethylpiperidine, or mixtures thereof.

9. The solid catalyst component of claim 1 , wherein the epoxy compound is represented as:

wherein:

a is 1, 2, 3, 4, or 5;

X is alkyl, F, Cl, Br, I; and

R a is H, alkyl, aryl, or cyclyl.

10. The solid catalyst component of claim 1 , wherein the halide-containing magnesium compound is selected from the group consisting of magnesium chloride, magnesium bromide, magnesium iodide, magnesium fluoride, and a mixture of any two or more thereof.

11. The solid catalyst component of claim 1 , wherein the organic phosphorus compound is represented by

wherein:

R 1 , R 2 , and R 3 are each independently C 1 -C 10 alkyl.

12. The solid catalyst component of claim 1 , wherein the organosilicon compound is a silane, siloxane or polysiloxane represented as Formula (II):

R n Si ( OR ′) 4-n   (II)

wherein:

each R is H, alkyl, or aryl;

each R′ is H, alkyl, aryl, or a SiRn'(OR′) 3-n ; and

n is 0, 1, 2, or 3.

13. The solid catalyst component of claim 1 further comprising a supportive donor, the supportive donor being different from the internal electron donor, the supportive donor comprising a monoester alone or in combination with a dialkyl ether, or an acrylate, the internal electron donor comprising an aryl diester.

14. A polymerization process comprising; polymerizing an olefin in the presence of the solid catalyst component of claim 1 , an organoaluminum compound, and optionally an external electron donor.

15. The polymerization process of claim 14 , wherein the polymerizing is further conducted in the presence of at least one selectivity control agent comprising a silane compound and optionally in the presence of an activity limiting agent.

16. The polymerization process of claim 14 further comprising producing polymer particles exhibit an aspect ratio of B/L3 greater than about 0.6.

17. A solid catalyst component for olefin polymerization, the solid catalyst component comprising:

a reaction product of a halide-containing magnesium compound with an epoxy compound;

an organic phosphorus compound;

a titanium compound; and

an organosilicon compound;

an internal electron donor comprising an aryl diester; and

a supportive donor comprising a monoester alone or in combination with a dialkyl ether, an acrylate, or a combination of a dialkyl ether and an acrylate;

wherein the solid catalyst component is free of side reaction products between a carboxylic acid or an anhydride thereof and a magnesium compound or a titanium compound, and wherein the solid catalyst component has a particle size from about 5 microns to about 70 microns (on a 50% by volume basis).

18. A solid catalyst system for olefin polymerization, the system comprising:

an organoaluminum compound;

at least one selectivity control agent;

an activity limiting agent; and

a solid catalyst component comprising:

a reaction product of a halide-containing magnesium compound with an epoxy compound;

an organic phosphorus compound;

a titanium compound;

an organosilicon compound; and

a internal electron donor comprising an aryl diester, a diether, a succinate, an organic acid ester, a polycarboxylic acid ester, a polyhydroxy ester, a heterocyclic polycarboxylic acid ester, an inorganic acid ester, an alicyclic polycarboxylic acid ester, a hydroxy-substituted carboxylic acid ester compound having 2 to 30 carbon atoms, or a compound having at least one ether group and at least one ketone group, or mixtures of any two or more thereof;

wherein the solid catalyst component is free of side reaction products between a carboxylic acid or an anhydride thereof and a magnesium compound or a titanium compound, and wherein the solid catalyst component has a particle size from about 5 microns to about 70 microns (on a 50% by volume basis).