CATALYST COMPONENT FOR PROPYLENE POLYMERIZATION WITH IMPROVED CATALYST PERFORMANCE

1 . An isolated solid catalyst component for olefin polymerization, the component comprising a reaction product of:

a halide-containing magnesium compound;

a titanium halide compound;

a supportive donor comprising a benzoate;

an internal electron donor; and

an activity control agent (ACA) comprising at least one of:

a first organosilicon compound containing Si—O groups being present in the catalyst component in an amount from about 0.1 to about 5% by weight;

an organic ester of a C 4 to C 30 aliphatic acid or a poly(alkene glycol) ester of a C 4 to C 30 aliphatic acid in amount from about 0.1% to about 15% by weight; and

an organo-aluminum compound containing an alkyl group,

wherein at least a part of the ACA is chemically bonded to the halide-containing magnesium compound.

2 . The solid catalyst component of claim 1 , wherein the supportive electron donor is present in the catalyst component in an amount from about 0.5% to about 7% by weight.

3 . The solid catalyst component of claim 1 , wherein the internal electron donor is present in the catalyst component in an amount from about 3% to about 25% by weight.

4 . The solid catalyst component of claim 1 , wherein the internal electron donor comprises a diester, a diether, a succinate, or any combination thereof.

5 . The solid catalyst component of claim 1 , wherein the halide-containing magnesium compound comprises magnesium chloride.

6 . The solid catalyst component of claim 1 , wherein the first organosilicon compound is a silane, siloxane or polysiloxane having the following chemical structure:

R n Si(OR′) 4-n

wherein:

each R is H, alkyl, or aryl;

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

n is 0, 1, 2, or 3.

7 . The solid catalyst component of claim 1 , wherein the internal electron donor is represented by the following formula:

wherein:

each of R 15 through R 20 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.

8 . The solid catalyst component of claim 1 , wherein the internal electron donor is represented by one of the following formulas:

where R 1 -R 4 , are the same or different and each R 1 -R 4 is selected from the group consisting of hydrogen, a substituted hydrocarboyl group having 1 to 20 carbon atoms, an unsubstituted hydrocarobyl having 1 to 20 carbon atoms, a substituted or unsubstituted aryl group having 6 to 20 carbons, an alkoxy group having 1 to 20 carbon atoms, a heteroatom and combinations thereof and at least one of R 1 -R 4 is not hydrogen; and

E 1 and E 2 are the same or different and each E 1 and E 2 is selected from the group consisting of a substituted hydrocarboyl group having 1 to 20 carbon atoms, an unsubstituted hydrocarobyl having 1 to 20 carbon atoms, a substituted or unsubstituted aryl group having 6 to 20 carbons, an alkoxy group having 1 to 20 carbon atoms, a heteroatom and combinations thereof

wherein X 1 and X 2 are each O, S, an alkyl group, or NR 5 and wherein R 5 is a hydrocarbyl group having 1 to 20 carbon atoms or is hydrogen;

wherein:

each of R 60 through R 65 are independently H, F, Cl, Br, I, alkyl, cycloalkyl, cycloalkylalkyl, aryl, aralkyl, heterocyclyl, heterocyclylalkyl, heteroaryl, or heteroarylalkyl; or

wherein each of R 66 through R 73 are independently H, F, Cl, Br, I, alkyl, cycloalkyl, cycloalkylalkyl, aryl, aralkyl, heterocyclyl, heterocyclylalkyl, heteroaryl, or heteroarylalkyl groups.

9 . The solid catalyst component of claim 1 , wherein the supportive electron donor has the following formula:

wherein R′ comprises an alkyl group, a cyclic group, an aryl group having from 1 to 20 carbon atoms, a heteroatom or a combination thereof, and wherein R″ comprises one or more substituted groups, each substituted group can comprise independently hydrogen, an alkyl group, a cyclic group, an aryl group having from 1 to 20 carbon atoms, a heteroatom, or a combination thereof.

10 . The solid catalyst component of claim 1 , further comprising a second organosilicon compound different from the first organosilicon compound.

11 . The solid catalyst component of claim 10 , wherein the second organosilicon compound comprises tetraethylorthosilicate and/or polydimethyl siloxane.

12 . The solid catalyst component of claim 1 , wherein the first organosilicon compound comprises dicyclopentyldimethoxysilane, cyclohexylmethyldimethoxysilane, n-propyltrimethoxysilane, trimethoxysilane, or any combination thereof.

13 . The solid catalyst component of claim 1 , wherein the ACA comprises an organosilicon compound and no organo-aluminum component is contained in the catalyst component.

14 - 16 . (Canceled)

17 . The solid catalyst component of claim 1 , wherein the ACA comprises an organic ester selected from the group consisting of isopropyl myristate, di-n-butyl sebacate, (poly) (alkylene glycols), mono-or di-myristates, pentyl valerate, and combinations thereof.

18 . The solid catalyst component of claim 1 , wherein the ACA comprises a combination of a) dicyclopentyldimethoxysilane, cyclohexylmethyldimethoxysilane, n-propyltrimethoxysilane, and/or trimethoxysilane and b) an organic ester selected from the group consisting of isopropyl myristate, di-n-butyl sebacate, (poly) (alkylene glycols), mono-or di-myristates, pentyl valerate, and combinations thereof.

19 - 21 . (canceled)

22 . A process for producing a solid catalyst component, the process comprising:

forming a catalyst precursor component by reacting a magnesium alkoxide Mg(OR) n X 2-n or magnesium alcoholate MgX 2 mR′OH with Ti(OR″) g X 4-g wherein X is Br, Cl, or I; n is 1, 2; m is 0.5-10; g is 0, 1, 2, 3, or 4; and R, R′, R″ are independently C1-C10 alkyl, the catalyst precursor containing a supportive electron donor and an internal electron donor;

reacting the catalyst precursor component with at least one of:

a first organosilicon compound having the following formula: R 2 nSi(OR 3 ) 4-n , wherein R 2 is H, alkyl, or aryl; each R 3 is alkyl, or aryl; n is 0, 1, 2 or 3 in hydrocarbon solvent;

an organic ester from a C 4 to C 30 aliphatic acid ester or a poly(alkene glycol) ester of a C 4 to C 30 aliphatic acid; or an alkyl aluminum compound; and

isolating the solid catalyst component.

23 . The process of claim 22 , further comprising isolating and or/drying the catalyst precursor compound before the reacting the catalyst precursor step.

24 . The process of claim 22 , wherein the supportive electron donor is present in the catalyst component in an amount from about 0.5% to about 7% by weight.

25 - 30 . (canceled)

31 . The process of claim 22 , further comprising incorporating a second organosilicon compound different from the first organosilicon compound into the catalyst precursor component.

32 - 34 . (canceled)

35 . A process for producing an olefin polymer, the process comprising polymerizing an olefin in the presence of an isolated solid catalyst component, the solid catalyst component comprising a reaction product of:

a halide-containing magnesium compound;

a titanium halide compound;

at least one internal electron donor; and

an activity control agent (ACA) comprising at least one of:

a first organosilicon compound containing Si—O groups being present in the catalyst component in an amount from about 0.1 to about 5% by weight;

an organic ester of a C 4 to C 30 aliphatic acid or a poly(alkene glycol) ester of a C 4 to C 30 aliphatic acid in amount from about 0.1% to about 15% by weight; and

an organo-aluminum compound containing an alkyl group, wherein at least a part of the ACA is chemically bonded to the halide-containing magnesium compound, and wherein the solid catalyst component is not prepared in a polymerization reactor.

36 - 51 . (canceled)