Aqueous Titanated Chromium Catalyst Synthesis
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Solution Overview
Problem
The existing methods for producing titanated chromium catalysts, particularly those involving titanium addition to chromium/silica catalysts, require prolonged drying steps that lead to VOC emissions, reduced efficiency, and batchwise processing, resulting in increased costs and loss of melt index potential.
Innovation Solution
A process involving the formation of a water-soluble titanium-silicon complex by contacting a silicon compound with water and an acid or base in a solvent, followed by combining with a titanium compound to create a titanated solid support and catalyst, allowing for continuous production without the need for prolonged drying steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If anhydrous route with titanium alkoxides is used, then titanium can be deposited onto chromium/silica catalyst, but prolonged drying steps are required which cause VOC emissions and increase processing time
Solution Approach 1:
The invention changes the chemical parameters of the deposition system by using water-soluble titanium salts instead of organic titanium alkoxides, and conducting the reaction in aqueous medium with controlled pH. This eliminates the need for prolonged drying steps and VOC emissions while maintaining effective titanium deposition on the chromium/silica catalyst.
Solution Approach 2:
The invention replaces the mechanical drying process (thermal evaporation of organic solvents) with a chemical precipitation process in aqueous medium. The titanium is deposited through controlled hydrolysis and precipitation reactions, eliminating the need for energy-intensive drying steps and reducing VOC emissions.
2Ease of manufacture
If anhydrous drying steps are used, then organics can be removed from solvent and alkoxide, but processing time increases and melt index potential is lost
Solution Approach 1:
The invention changes the solvent system from organic to aqueous, allowing removal of water-soluble byproducts through simple filtration or decantation instead of prolonged thermal drying. This dramatically reduces processing time and preserves melt index potential while achieving effective organic removal.
Solution Approach 2:
The invention enables continuous processing by eliminating the batch-wise drying steps. The aqueous-based deposition and drying can be performed more quickly and continuously, improving productivity while maintaining the effectiveness of organic removal.
3Reliability
If batchwise processing is used, then titanium addition can be controlled, but cost increases and efficiency decreases
Solution Approach 1:
The invention enables continuous processing operations where titanium salts are added continuously to a flowing slurry of chromium/silica catalyst in aqueous medium. This maintains precise control over titanium addition while dramatically improving production efficiency and reducing costs compared to batchwise processing.
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 the production of titanated chromium catalysts with higher melt index potential, reducing costs and environmental impact while maintaining efficiency through continuous processing and minimizing VOC emissions.
Implementation Method 1
contacting a silicon compound with water and an acid or a base in a solvent to form a first solution containing a partially-hydrolyzed silicon material
Implementation Method 2
contacting a titanium compound with the first solution containing the partially-hydrolyzed silicon material to form a second solution containing a titanium-silicon complex
Data Source
AI summary
Methods for synthesizing a water-soluble titanium-silicon complex are disclosed herein. The titanium-silicon complex can be utilized to produce titanated solid oxide supports and titanated chromium supported catalysts. The titanated chromium supported catalysts subsequently can be used to polymerize olefins to produce, for example, ethylene based homopolymer and copolymers.