Borate Activator Oligomerisation Catalyst System
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Solution Overview
Problem
Existing oligomerization processes for olefinic compounds face challenges with low reaction rates and high solid formation when using aluminum-containing activators at low concentrations, leading to increased costs and inefficiencies.
Innovation Solution
The use of borate activators in combination with a chromium-based catalyst system in an aliphatic solvent, which enhances catalyst activation, efficiency, and reduces solid formation, thereby improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If aluminum-containing activators are used at low concentrations to reduce costs, then activator cost is reduced, but reaction rate decreases and solid formation increases
Solution Approach 1:
The patent changes the chemical parameter of the activator from aluminum-containing compounds to boron-containing compounds. This parameter change enables the system to achieve high reaction rates at low activator concentrations, resolving the contradiction between cost reduction and productivity maintenance. The boron-based activator provides superior catalytic activity that allows process operation at lower concentrations without sacrificing reaction rate.
Solution Approach 2:
The patent employs boron-containing activators that can be used at very low concentrations (e.g., 0.01-10 mmol/L), effectively treating them as highly efficient, low-cost additives. The low concentration requirement reduces material costs while the high activity maintains productivity, making the activator economically viable despite its temporary role in the catalytic cycle.
2Loss of substance
If aluminum-containing activators are used at low concentrations to reduce costs, then activator cost is reduced, but solid formation increases
Solution Approach 1:
The patent changes the activator chemistry from aluminum-based to boron-based compounds. This parameter change fundamentally alters the catalytic behavior, suppressing solid formation (polymer precipitation) while maintaining low cost operation. The boron-based system provides better control over polymerization kinetics, preventing excessive solid formation even at low activator concentrations.
3Reliability
If aluminum-containing activators are used to activate catalyst, then catalyst activation is achieved, but process economics are negatively impacted
Solution Approach 1:
The patent replaces expensive aluminum-containing activators with cheaper boron-containing activators that can be used at lower concentrations. The boron-based activators maintain effective catalyst activation while significantly reducing material costs, improving overall process economics. The lower concentration requirement (0.01-10 mmol/L) further amplifies the economic benefit.
Solution Approach 2:
The patent changes the activator parameter from aluminum-based to boron-based chemistry. This parameter change maintains the essential function of catalyst activation while altering the economic profile. The boron-based system achieves comparable or superior activation efficiency at lower cost, resolving the contradiction between reliable catalyst activation and process economics.
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 results in increased catalyst productivity and reduced solid formation, enhancing the efficiency and cost-effectiveness of the oligomerization process by utilizing borate activators that are soluble in aliphatic solvents, leading to improved reaction rates and product yields.
Implementation Method 1
The catalyst activator may be an organoboron compound which includes a cation and a non-coordinating anion, wherein the cation is a Bronsted acid capable of donating a proton
Implementation Method 2
a catalyst activator which generates an active catalyst when the activator is combined with the catalyst
Data Source
AI summary
This invention relates to the oligomerization of olefinic compounds in the presence of an activated oligomerization catalyst. The invention also extends to a particular manner for providing an activated oligomerization catalyst. According to the present invention, there is provided a process for producing an oligomeric product by the oligomerization of at least one olefinic compound, the process including (a) providing an activated oligomerization catalyst by combining, in any order, iii) a source of chromium, ιv) a ligating compound of the formula (R1)mX1(Y)X2(R2)n wherein X1 and X2 are independently an atom selected from the group consisting of nitrogen, phosphorus, arsenic, antimony, bismuth, oxygen, sulphur and selenium or said atom oxidized by S, Se, N or O where the valence of X1 and/or X2 allows for such oxidation, Y is a linking group between X1 and X2 which linking group contains at least one nitrogen atom which is directly bonded to X1 or X2, m and n are independently 0, 1 or a larger integer, and R1 and R2 are independently hydrogen, a hydrocarbyl group, an organoheteryl group or a heterohydrocarbyl group, and the respective R1 groups are the same or different when m>1, and the respective R2 groups are the same or different when n>1, in) a catalyst activator which is an organoboron compound including a cation and a non-coordinating anion of the general formula [(R10)xL*-H]+[B(R20)4]− wherein L* is an atom selected from the group consisting of N, S and P, the cation [(R10)x L*-H]* is a Bronsted acid, x is an integer 1, 2 or 3, each R10 is the same or different when x is 2 or 3 and each is a —H, hydrocarbyl group or a heterohydrocarbyl group, provided that at least one of R10 comprises at least 6 carbon atoms and provided further that the total number of carbon atoms in (R10)x collectively is greater than 12, R20 independently at each occurrence is selected from the group consisting of hydride, dialkylamido, halide, alkoxide, aryloxide, hydrocarbyl, halosubstituted-hydrocarbyl radicals, halosubstituted-alkoxide, halosubstituted-aryloxide and a halosubstituted aromatic ring moiety with at least one halide substituent on the aromatic ring, and vi) an aliphatic solvent, and (b) contacting the at least one olefinic compound with the activated oligomerization catalyst to produce an oligomeric product.