Bio-Based Catalyst Composition for Polymer Control in Ethylene Dimerization

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Solution Overview

Problem

Existing ethylene dimerization processes face significant polymer formation issues, leading to operational downtime, frequent process interruptions, and increased maintenance costs due to polymer residues that accumulate and impede reactor functionality.

Innovation Solution

A catalyst composition comprising a titanium alkoxide compound, an alkyl aluminum compound, an organic ether, and a bio-based polymer suppressant, specifically isohexide-derived ethers, is developed to reduce polymer formation during ethylene dimerization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional ethylene dimerization process is used, then 1-butene production is achieved, but polymer formation occurs leading to operational downtime and maintenance issues

Engineering Contradiction:

Improve1-butene production efficiencyVSAvoidoperational continuity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A silane compound is introduced as an intermediary substance that selectively interacts with growing polymer chains through silane-polymer coupling reactions. This mediator prevents polymer accumulation on reactor surfaces while maintaining the dimerization reaction efficiency, thereby ensuring operational continuity without sacrificing 1-butene production

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The catalyst system parameters are modified by incorporating specific silane compounds with controlled molecular weights and functional groups. This parameter change alters the reaction pathway to favor dimerization over polymerization, reducing polymer formation while maintaining high 1-butene yield and operational reliability

Inventive Principle:

Principle #35Parameter changes

2Productivity

If extended residence time is used to improve conversion, then more polymer residues are formed requiring frequent process interruptions

Engineering Contradiction:

Improveethylene conversion rateVSAvoidprocess interruption frequency

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The silane compound converts the harmful polymerization side reaction into a beneficial process by controlling polymer chain growth through silane termination. This allows extended residence times to achieve high conversion while the silane-controlled polymer formation does not lead to fouling, eliminating the need for frequent interruptions

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If polymer suppressant is added to reduce polymer formation, then operational downtime is reduced, but catalyst system complexity increases

Engineering Contradiction:

Improveoperational continuityVSAvoidcatalyst composition complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The silane compound serves multiple functions simultaneously: it acts as a polymer suppressant by coupling with growing polymer chains, maintains catalyst stability, and does not interfere with the dimerization reaction. This multi-functionality achieves operational continuity without significantly increasing catalyst system complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 composition effectively suppresses polymer formation, enhancing operational efficiency by reducing downtime and maintaining high selectivity and conversion for 1-butene production.

Implementation Method 1

The ethylene dimerization process occurs in the liquid phase using a homogeneous catalytic system, such as Ti(OC 4 H 9 ) 4 -Al(C 2 H 5 ) 3 along with an electron donor

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

Triethylaluminum (TEA), represented as Al(C 2 H 5 ) 3, functions as an activator in this system. It facilitates the release of free coordination sites within the titanate complex, forming one or more Ti-C bonds

Methodology Applied

Scientific EffectCoordination chemistry:

Implementation Method 3

The catalyst modifiers, which are electron donor ligands, act as Lewis bases or polar organic compounds. When introduced into the catalyst system, they enhance the selectivity for the desired reaction

Methodology Applied

Scientific EffectSteric hindrance:

Implementation Method 4

The catalyst modifiers, which are electron donor ligands, act as Lewis bases or polar organic compounds

Methodology Applied

Scientific EffectLewis base interaction:

Data Source

PatentEP4616945A1A catalyst composition for reduction of polymer formation in etthylene dimerization

Publication Date: 2025.09.17 HINDUSTAN PETROLEUM CORP LTD

Figure 1~2

AI summary

The present disclosure relates to a catalyst composition for reduction of polymer formation in ethylene dimerization comprising: a bio-based modifier as polymer suppressant for ethylene dimerization; a titanate compound; an alkyl aluminum compound; and an organic ether. The bio-based polymer suppressant is a compound selected from a group consisting of an isohexide derived ether compound of formula I, and an isomer of formula I or combination of thereof, wherein R1 and R2 are independently selected from a group consisting of CH3, C2H5, n-C3H7, i-C3H7, n-C4H9, i-C4H9, Ph, C1 to C8 alkyl groups, an aryl group, and a heteroaryl group or combination of thereof.