Long-Chain Alkoxy Activators for Aliphatic Olefin Polymerization
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Solution Overview
Problem
Existing olefin polymerization catalysts based on metallocenes require aromatic solvents for activation, which are costly to remove and complicate the polymerization process, and are insoluble in aliphatic hydrocarbons, making them difficult to handle and meter accurately.
Innovation Solution
Development of activators and catalyst systems that are soluble in aliphatic solvents, comprising compounds with specific aryl and alkyl groups, allowing for catalysts that can be used in aliphatic hydrocarbon solvents without the need for aromatic solvents, enhancing solubility and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ionic salt activators are used for olefin polymerization, then catalyst activity is improved, but solubility in aliphatic hydrocarbons deteriorates
Solution Approach 1:
The invention modifies the chemical structure of the ionic salt activator by introducing long chain alkoxy groups (C10-C30) to the cation, which fundamentally changes the solubility parameters of the compound. This structural modification allows the activator to dissolve in aliphatic hydrocarbons while maintaining its ionic character and catalytic activity, thus resolving the contradiction between catalyst activity and solubility.
Solution Approach 2:
The activator represents a composite structure combining the ionic functional group (for catalytic activity) with long chain alkoxy hydrophobic groups (for solubility in aliphatic hydrocarbons). This composite molecular architecture integrates both required properties: the ionic center provides catalyst activation capability while the alkoxy chains provide compatibility with aliphatic hydrocarbon solvents.
2Reliability
If aromatic solvents are used to dissolve activators, then solubility is improved, but process complexity and cost increase due to devolatilization requirements
Solution Approach 1:
The invention changes the solvent parameter from aromatic to aliphatic hydrocarbon by modifying the activator's molecular structure. This parameter change in the activator enables compatibility with simpler aliphatic solvents, eliminating the need for complex devolatilization processes required when using aromatic solvents, thus reducing overall process complexity.
3Productivity
If activators are used in oily form, then catalyst activity is maintained, but ease of operation deteriorates due to difficult handling and metering
Solution Approach 1:
The invention changes the physical state parameter of the activator from oily to soluble form by introducing long chain alkoxy groups. This structural modification enables the activator to form clear solutions in aliphatic hydrocarbons, transforming it from an unmanageable oily substance into an easily handleable and precisely meterable solution, while preserving catalytic activity.
Data Source
AI summary
Activators may comprise compounds represented by the Formula [Ar(EHR1R2)(OR3)]d+[Mk+Qn]d, wherein: Ar is an aryl group; E is nitrogen or phosphorous; R1 is a C1-C30, optionally substituted, linear alkyl group; R2 is a C1-C30, optionally substituted, linear alkyl group; R3 is a C10-C30, optionally substituted, linear alkyl group; M is an element selected from group 13 of the Periodic Table of the Elements; d is 1, 2 or 3; k is 1, 2, or 3; n is 1, 2, 3, 4, 5, or 6; n−k=d; and each Q is independently hydride, bridged or unbridged dialkylamido, halide, alkoxide, aryloxide, hydrocarbyl, substituted hydrocarbyl, halocarbyl, substituted halocarbyl, or halosubstituted-hydrocarbyl radical. Catalysts systems may comprise these activators and methods of preparing polyolefins may use these catalysts systems.