Patent ID: 7211535

Claim:
A process for preparing an alpha-olefin polymerization catalyst composition having a productivity of greater than 1,500 g of polymer per gram of catalyst under standard gas phase operations used to manufacture an, ethylene hexene copolymer resin having a density of 0.918 g/cc and an Ml of 1 g/10 min. comprising contacting at a temperature from 0° C. to 100° C. a support which has been heat treated to remove adsorbed water and having a residual surface hydroxyl content from 0.1 to 5 mmol/g of support, which support has been subsequently treated with an aluminum compound reactive with the surface hydroxyl groups to provide from 0.5 to 2.5 wt % Al on the support, in an inert hydrocarbyl solvent or diluent with or without isolation of the treated support from the hydrocarbyl solvent or diluent with: a transition metal compound, a magnesium halide, prepared by reacting in situ an alkyl magnesium compound of the formula (R 5 ) e Mg X 2-e wherein each R 5 is independently a C 1-8 alkyl radical and e is 1 or 2 and X is a chlorine or bromine atom, with a reactive organic halide selected from the group consisting of CCI 4 and C 1-6 alkyl halides and mixtures thereof, a second aluminum alkyl compound and an electron donor and separating the resulting catalyst from the inert hydrocarbyl solvent or diluent provided that the order of reagent addition to the support meets the following conditions: (i) the transition metal compound cannot be added first; (ii) when the Mg compound is added first, the transition metal compound cannot be added second; (iii) when the second aluminum alkyl is added first, the transition metal compound cannot be added second; (iv) when the Mg compound and the second aluminum alkyl compound are added first and second, in any order, the transition metal compound cannot be added third; (v) the transitional metal compound must be added after the reactive organic halide; (vi) the transition metal compound must be added after the alkyl magnesium compound; (vii) the electron donor cannot be added last; (viii) the reactive organic halide cannot be added last; (ix) if the reactive organic halide is added first the second aluminum alkyl compound cannot be added second; (x) if the second aluminum alkyl compound is added first the reactive organic halide cannot be added second; and (xi) when the transition metal is added last, the second aluminum alkyl and Mg compounds cannot be added third or fourth, in any order.