Ziegler-Natta Catalyst Components Using Non-Toxic Electron Donors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The use of phthalates as internal donors in Ziegler-Natta catalysts for propylene polymerization has raised toxicity concerns, necessitating the development of alternative electron donor compounds that maintain or improve performance without worsening stereospecificity.
Innovation Solution
The development of catalyst components comprising Mg, Ti, and specific electron donor compounds of the formula (I) and (II), which include hydrocarbon groups and heteroatoms, with a preferred syn configuration, supported on a Mg dihalide, offering improved affinity and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phthalates are used as internal donors in Ziegler-Natta catalysts, then good catalytic performance and high isotacticity are achieved, but toxicity problems arise
Solution Approach 1:
The patent replaces traditional phthalate internal donors with alternative electron donor compounds that have similar catalytic performance but without the toxicity issues. The new donors use different chemical structures (esters of dicarboxylic acids with specific chain lengths and branching) that achieve the same functional purpose without harmful effects, effectively substituting a harmful material with a safe alternative.
Solution Approach 2:
The invention changes the chemical parameters of the internal donor by using esters of dicarboxylic acids with specific chain lengths (C3-C20) and specific structural features (branching at positions 2 and 4). By modifying the molecular structure parameters while maintaining the electron donor function, the catalyst achieves high isotacticity without the toxicity associated with phthalates.
2Object-affected harmful factors
If alternative electron donor compounds are used to replace phthalates, then toxicity is reduced, but stereospecificity may worsen
Solution Approach 1:
The patent carefully optimizes the structural parameters of the alternative electron donors, specifically using esters of dicarboxylic acids with chain lengths of C3-C20 and specific branching patterns at positions 2 and 4. These parameter adjustments ensure that the new donors provide adequate steric control for high isotacticity while eliminating the toxicity of phthalates.
Solution Approach 2:
The invention introduces specific local structural features in the electron donor molecules, such as branching at positions 2 and 4 of the dicarboxylic acid chain, which create localized steric environments that promote stereospecific polymerization. This local structural quality ensures high isotacticity is maintained despite the overall molecular structure being different from phthalates.
3Adaptability or versatility
If a broad class of ester compounds is used as internal donors, then versatility is improved, but performance consistency deteriorates
Solution Approach 1:
The patent defines a systematic family of compounds with controlled parameter ranges: dicarboxylic acids with chain lengths of C3-C20, with specific branching at positions 2 and 4. By establishing these parameter boundaries, the invention provides versatility in selecting different chain lengths and substituents while ensuring consistent high performance through the mandatory branching structure that controls steric environment.
Solution Approach 2:
The invention segments the broad class of ester compounds into a specific systematic family based on the dicarboxylic acid backbone with controlled chain lengths and specific branching patterns. This segmentation approach allows for systematic variation of parameters (chain length, substituents) while maintaining the core structural features that ensure consistent catalytic performance.
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 new catalyst components exhibit enhanced stereospecificity and performance, with the syn configuration of the electron donors showing higher affinity and improved catalyst performances, potentially replacing phthalates while minimizing toxicity issues.
Implementation Method 1
the syn configuration of the electron donors showing higher affinity and improved catalyst performances
Data Source
AI summary
Catalyst component for the polymerization of olefins comprising Mg, Ti and an electron donor compound of the following formula (I)In which R1 groups are selected from C1-C15 hydrocarbon groups, R8 groups, equal or different to each other, are selected from hydrogen, halogen and C1-C15 hydrocarbon groups, optionally containing an heteroatom selected from halogen, O, P, S, N and Si and L is a divalent hydrocarbon group optionally containing heteroatoms selected from halogen, O, P, S, N and Si.