Alkoxymagnesium Catalyst for Olefin Polymerization
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Solution Overview
Problem
Existing solid catalyst components for olefin polymerization, particularly those containing alkoxymagnesium, face challenges in reducing fine-powder polymer formation and achieving uniform particle size distribution, leading to process inefficiencies and environmental concerns due to byproduct chemicals and solvent recovery issues.
Innovation Solution
Development of an alkoxymagnesium with secondary particles composed of primary particles having an average diameter of less than 1 µm, a specific surface area of less than 50 m²/g, and a particle size distribution index of 1 or less, produced through a method involving metal magnesium reaction with alcohol and subsequent contact with carboxylic acid esters in an organic solvent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional alkoxymagnesium is used as solid catalyst component, then polymerization activity is maintained, but fine-powder polymer formation increases and particle size distribution becomes broad
Solution Approach 1:
The invention changes the particle size parameters of the alkoxymagnesium from conventional broad distribution to a controlled narrow distribution (D90-D10)/D50 ≤ 1.0, while maintaining polymerization activity through optimized particle characteristics
Solution Approach 2:
The invention segments the alkoxymagnesium into secondary particles with controlled primary particle aggregates, creating a hierarchical particle structure that reduces fine powder formation while maintaining catalytic activity through the segmented architecture
2Manufacturing precision
If dialkoxymagnesium powder is treated with polyvalent carboxylic acid halide or monocarboxylic acid halide, then fine-powder polymer formation is suppressed to some extent, but further reduction requires additional complex process steps
Solution Approach 1:
The invention performs preliminary particle size control during the formation of alkoxymagnesium itself, creating secondary particles with controlled primary particle aggregates before the catalyst is used, thereby preventing fine powder formation at the source rather than addressing it as a subsequent problem
Solution Approach 2:
The invention extracts and removes the problematic fine powder component by controlling the particle formation process to prevent it from being generated in the first place, separating the useful catalytic function from the harmful fine powder byproduct
3Manufacturing precision
If water or hydrate is used for preparation of dialkoxymagnesium powder composition, then fine-powder polymer of 45 µm or less is reduced, but polymerization activity decreases due to extremely increased titanium content
Solution Approach 1:
The invention changes the particle size parameters to control the balance between fine powder reduction and polymerization activity, achieving optimal performance by adjusting the secondary particle structure rather than relying on water treatment that causes titanium accumulation
4Manufacturing precision
If sequential reaction step and surfactant contacting step are carried out, then fine-powder polymer formation is suppressed to some extent, but solvent recovery becomes difficult due to byproduct chemicals in liquid waste
Solution Approach 1:
The invention extracts and eliminates the need for surfactant and complex washing steps by controlling particle formation directly, thereby removing the source of byproduct chemicals that contaminate the liquid waste and make solvent recovery difficult
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 effectively reduces fine-powder polymer formation, enhances particle size distribution, and improves polymerization activity while simplifying waste management and solvent recovery, resulting in a more efficient and environmentally friendly olefin polymerization process.
Implementation Method 1
reacting metal magnesium with an alcohol in the presence of a catalyst to obtain a solid
Implementation Method 2
contacting the solid with one or more carboxylic acid esters in an organic solvent to form a suspension
Implementation Method 3
a solid catalyst component for olefin polymerization, an olefin polymerization catalyst, and a method for producing an olefin polymer
Data Source
Figure 1~2
AI summary
There is provided a novel alkoxymagnesium which, when used as a constituent of a solid catalyst component for olefin polymerization to polymerize an olefin, may reduce the formation rate of a fine powder and may form a polymer having an excellent particle size distribution under high polymerization activity. The alkoxymagnesium is characterized by comprising secondary particles each of which is an aggregate of primary particles having an average particle diameter of less than 1 µm and by having a ratio represented by the average particle diameter of the primary particles/the average particle diameter of the secondary particles of 0.1 or less, a total pore volume of 0.5 to 1 cm3/g, a specific surface area of less than 50 m2/g, and a particle size distribution index (SPAN) 1 or less.