Aliphatic Hydrocarbon Solvent Suspension for Catalyst Delivery
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Solution Overview
Problem
Current polymerization processes face challenges in achieving high catalyst efficiency and productivity due to issues like catalyst degradation, poor solubility, and the need for aromatic solvents, which increase costs and operational complexities.
Innovation Solution
A method of passing a homogeneous single-site catalyst to a solution polymerization reactor as a suspension in an aliphatic hydrocarbon solvent or wax, allowing for higher catalyst concentrations without the need for aromatic solvents, thereby improving catalyst utilization and polymer yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If aromatic solvents are used as catalyst carrying medium, then catalyst solubility and utilization efficiency are improved, but operational costs increase and additional solvent separation requirements are added
Solution Approach 1:
The patent changes the chemical parameter of the solvent from aromatic to aliphatic hydrocarbon, fundamentally altering the solvent-catalyst interaction. This parameter change enables the catalyst to achieve sufficient solubility and utilization in aliphatic solvents without requiring aromatic solvents, thereby eliminating the need for expensive solvent separation operations while maintaining high catalyst efficiency
Solution Approach 2:
The patent employs aliphatic hydrocarbon solvents which are simpler and cheaper to handle compared to aromatic solvents. These solvents do not require complex separation and recovery systems, effectively replacing expensive aromatic solvent systems with more economical aliphatic alternatives that can be used directly in the polymerization process
2Productivity
If aromatic solvents are used as catalyst carrying medium, then catalyst solubility is improved, but process complexity increases due to solvent recovery and recycle requirements
Solution Approach 1:
The patent changes the chemical parameter of the solvent from aromatic to aliphatic hydrocarbon, fundamentally altering the solvent-catalyst interaction. This parameter change enables the catalyst to achieve sufficient solubility and utilization in aliphatic solvents without requiring aromatic solvents, thereby eliminating the need for expensive solvent separation operations while maintaining high catalyst efficiency
Solution Approach 2:
The patent extracts the problematic aromatic solvent component from the system and replaces it with aliphatic hydrocarbon solvents. This extraction eliminates the need for complex solvent recovery and recycle systems, simplifying the overall process by removing the aromatic solvent handling infrastructure entirely
3Productivity
If catalyst concentration is increased to improve productivity, then polymer yield increases, but catalyst degradation and plugging of feed lines occur
Solution Approach 1:
The patent changes the solvent parameter from aromatic to aliphatic hydrocarbon, which fundamentally alters the catalyst-solvent interaction. This parameter change allows the catalyst to maintain stability and resist degradation even at higher concentrations in aliphatic solvents, enabling increased polymer yield without sacrificing catalyst reliability
Solution Approach 2:
The aliphatic hydrocarbon solvent acts as an intermediary medium that facilitates high catalyst concentration delivery without causing plugging or degradation. The solvent mediates between the high catalyst concentration requirement for productivity and the catalyst stability requirement, allowing both conditions to be satisfied simultaneously
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables high polymer yields with reduced solvent usage and operational costs, maintaining catalyst efficiency and productivity while avoiding the drawbacks of aromatic solvents.
Implementation Method 1
passing a homogeneous single-site catalyst to a solution polymerization reactor as a suspension in an aliphatic hydrocarbon solvent or wax
Data Source
AI summary
Disclosed is a solution polymerization process, or, alternatively, a method of delivering powder catalysts to a solution polymerization reactor, comprising combining a homogeneous single-site catalyst precursor with α-olefin monomers to form a polyolefin, wherein the homogeneous single-site catalyst precursor is in the form of (i) a dry powder, (ii) suspended in a aliphatic hydrocarbon solvent, or (iii) suspended in an oil or wax, wherein the homogeneous single-site catalyst precursor is at a concentration greater than 0.8 mmole/liter when suspended in the aliphatic hydrocarbon solvent prior to entering the solution polymerization reactor.