Substituted Amide Ester Procatalyst for Broad MWD Propylene
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Solution Overview
Problem
The production of olefin-based polymers with broad molecular weight distribution using Ziegler-Natta catalysts is limited by the need for rigorous process control and multiple reactor systems, which restricts the diversity and sophistication of applications for these polymers.
Innovation Solution
The development of procatalyst compositions containing a substituted amide ester as an internal electron donor, which enhances catalyst activity and selectivity, allowing for the production of propylene-based olefins with high isotacticity and broad molecular weight distribution in a single reactor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional Ziegler-Natta catalyst compositions are used to produce olefin-based polymers with broad molecular weight distribution, then the desired polymer properties are achieved, but rigorous process control and multiple reactor systems are required
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the catalyst system. Specifically, it uses a procatalyst comprising titanium halide supported on magnesium chloride with substituted amide ester internal electron donors, combined with organoaluminum cocatalysts in specific molar ratios. This chemical parameter modification enables broad MWD production in a single reactor, resolving the contradiction between manufacturing precision and device complexity.
2Manufacturing precision
If conventional Ziegler-Natta catalyst compositions are used to produce olefin-based polymers with broad molecular weight distribution, then the desired polymer properties are achieved, but rigorous process control is required
Solution Approach 1:
The patent changes the operational parameters by eliminating the need for rigorous process control through optimized catalyst composition. The specific formulation with substituted amide ester internal electron donors and controlled molar ratios of catalyst components creates a self-regulating system that produces broad MWD polymers under simpler, more easily controlled conditions, resolving the contradiction between manufacturing precision and ease of operation.
3Manufacturing precision
If multiple reactor systems are used to produce olefin-based polymers with broad molecular weight distribution, then the desired polymer properties are achieved, but equipment requirements and process constraints increase
Solution Approach 1:
The patent applies the merging principle by combining multiple catalyst functions into a single integrated procatalyst system. The titanium halide supported on magnesium chloride with substituted amide ester internal electron donors performs multiple catalytic functions simultaneously, enabling broad MWD production in one reactor rather than requiring multiple reactors in series, thus resolving the contradiction between manufacturing precision and productivity.
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 use of substituted amide ester-containing procatalyst compositions improves catalyst activity and selectivity, enabling the production of propylene-based polymers with desired properties in a more efficient and less equipment-intensive process, reducing process constraints and eliminating the need for phthalate components.
Implementation Method 1
The internal electron donor includes a substituted amide ester... enhances catalyst activity and selectivity... produce propylene-based olefins with high isotacticity and broad molecular weight distribution
Data Source
AI summary
Disclosed are procatalyst compositions having an internal electron donor which includes a substituted amide ester and optionally an electron donor component. Ziegler-Natta catalyst compositions containing the present procatalyst compositions exhibit improved catalyst activity and/or improved catalyst selectivity and produce propylene-based olefins with broad molecular weight distribution.