Universal Alpha-Olefin Polymerization Catalyst Composite Internal Electron Donor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current industrial Ziegler-Natta catalysts for olefin polymerization face challenges in developing internal electron donors that are universally applicable, stable, cost-effective, and capable of producing polyolefins with varying grades and special properties, due to limited availability and performance of single electron donors, and lack of rational methods for preparing composite catalyst components.
Innovation Solution
A composite internal electron donor comprising di-(n)isobutyl phthalate and 9,9-bis(methoxymethyl)fluorene is used in a magnesium chloride support catalyst component, combined with triethyl aluminum and an external electron donor, to create a universal industrial catalyst suitable for various polymerization processes, allowing for adjustable performance and production of polyolefins with specific properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single internal electron donor is used in the catalyst, then the catalyst structure is simple and easy to manufacture, but the catalyst performance is limited and cannot satisfy various growing grades and special performance requirements
Solution Approach 1:
The patent employs a composite internal electron donor system comprising two distinct electron donors: (1) a first electron donor with specific steric and electronic properties, and (2) a second electron donor with different properties. This composite structure combines the advantages of both donors, enabling the catalyst to produce poly-alpha-olefins with varying grades and special performances while maintaining structural feasibility for industrial manufacture
Solution Approach 2:
The composite internal electron donor system is designed to be universally applicable across different poly-alpha-olefin production requirements. By selecting electron donors with complementary properties, the catalyst can satisfy various growing grades and special performance demands, making it a multi-functional solution for diverse polymerization applications
2Ease of manufacture
If di-(n)isobutyl phthalate is used as internal electron donor, then the catalyst has good overall performance and moderate price, but it presents safety hazards and lacks special performance for polymers
Solution Approach 1:
The patent combines di-(n)isobutyl phthalate (providing cost-effectiveness and good overall performance) with 9,9-bis(methoxymethyl)fluorene (providing high catalyst activity, low polymerization temperature capability, and high molecular weight polymers). This composite internal electron donor system reduces safety hazards while maintaining cost-effectiveness and adding special performance capabilities that neither donor alone could provide
3Productivity
If 9,9-bis(methoxymethyl)fluorene is used as internal electron donor, then the catalyst achieves high activity and produces high molecular weight polyolefins, but it is expensive and cannot serve as a universal catalyst for various processes
Solution Approach 1:
The patent uses 9,9-bis(methoxymethyl)fluorene in combination with di-(n)isobutyl phthalate in a composite internal electron donor system. This combination allows the catalyst to achieve high activity and produce high molecular weight polyolefins while reducing production cost by incorporating the more cost-effective di-(n)isobutyl phthalate, making it economically viable for universal industrial application
4Adaptability or versatility
If a composite of two electron donors is used as internal electron donor, then the catalyst can produce synergistic effect and adjustable performance, but the catalyst structure and preparation method become more complex
Solution Approach 1:
The patent employs a composite internal electron donor system with two electron donors that can be incorporated into the catalyst component through established preparation methods. The composite structure enables synergistic effects and adjustable performance by varying the ratios and types of electron donors, while the preparation complexity is managed through systematic approaches to catalyst component fabrication
Solution Approach 2:
The patent achieves performance adjustability by varying parameters such as the types, ratios, and amounts of the two electron donors in the composite internal electron donor system. This allows optimization of catalyst performance for different poly-alpha-olefin grades and special performances without fundamentally changing the catalyst preparation methodology
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
The catalyst exhibits wide applicability across industrial processes, reduced safety hazards, and efficient production of polypropylene with improved properties, such as high tacticity and molecular weight, while minimizing waste and resource consumption.
Implementation Method 1
the internal electron donor plays a key action in adjusting the catalyst activity and the structure of the poly-alpha-olefins
Implementation Method 2
titanium-containing magnesium chloride support catalyst component comprises an internal electron donor... for polymerization and copolymerization of olefins, especially alpha-olefins
Data Source
AI summary
Disclosed are a universal alpha-olefin polymerization industrial catalyst, and an application thereof, specifically an industrial production catalyst which consists of (A) a solid catalyst component, (B) a cocatalyst organoaluminium compound and (C) an external electron donor compound, and is used for various alpha-olefin polymerization or copolymerization processes. The solid catalyst component (A) is prepared from a dibutyl phthalate or diisobutyl phthalate and 9,9-bis(methoxymethyl)fluorene composite internal electron donor. A hydrocarbyl alkoxy silicon, an organic acid ester or a hydrocarbyl alkoxy silicon and organic acid ester composite acts as the external electron donor component (C). The solid catalyst component (A), the cocatalyst organoaluminium compound (B) and the external electron donor compound (C) are used together in industrial devices for various alpha-olefin polymerization or copolymerization processes to produce new grades of poly-alpha-olefins.