Polymerization Catalyst Preparation Reducing HRVOC Emissions
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Solution Overview
Problem
Current methods for producing olefin polymerization catalysts result in the emission of highly reactive volatile organic compounds (HRVOCs), which contribute to ozone formation and require costly regulatory compliance, necessitating the development of processes that reduce HRVOC emissions.
Innovation Solution
A method involving calcining a silica support, contacting it with titanium alkoxide and a chromium-containing compound, followed by a polyol, and subsequent calcination to form a polymerization catalyst, while minimizing HRVOC emissions by less than 0.1 wt.%, involves forming a titanated support and then a polyol-associated titanated support (PATS) before adding chromium and drying, then calcining to produce the catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional catalyst preparation methods are used, then catalyst production is achieved, but highly reactive volatile organic compounds (HRVOCs) are emitted during the process
Solution Approach 1:
The patent extracts and eliminates the harmful HRVOC emission component from the catalyst preparation process by replacing traditional organic solvent-based impregnation methods with aqueous-based methods, thereby removing the source of HRVOC emissions while maintaining catalyst production effectiveness
Solution Approach 2:
The patent changes the chemical composition parameter of the impregnation solution from organic-based to aqueous-based, fundamentally altering the process to eliminate HRVOC emissions. This parameter change transforms the process from harmful to environmentally compliant
2Object-affected harmful factors
If processes that reduce HRVOC emissions are developed, then environmental compliance is improved, but process complexity may increase
Solution Approach 1:
The patent introduces water as an intermediary solvent to replace organic solvents in the impregnation process. This intermediary substitution achieves HRVOC emission reduction while maintaining process simplicity, as aqueous methods are equally straightforward to implement
Solution Approach 2:
The patent converts the potential harm of using simple aqueous impregnation (which might be perceived as less effective) into a benefit by demonstrating that water-based methods achieve both emission reduction and effective catalyst formation, eliminating the need for complex additional equipment or procedures
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 method significantly reduces HRVOC emissions during catalyst production, achieving emissions less than 0.1 wt.%, thereby improving process economics and compliance with environmental regulations.
Implementation Method 1
calcining a silica support at temperature in the range of from about 100 °C to about 500 °C to form a precalcined silica support
Implementation Method 2
contacting the precalcined silica support with a titanium alkoxide to form a titanated support
Implementation Method 3
contacting the titanated support with a polyol to form a polyol associated titanated support (PATS)
Implementation Method 4
drying the polymerization catalyst precursor to form a dried polymerization catalyst precursor
Implementation Method 5
calcining the dried polymerization catalyst precursor to produce a polymerization catalyst
Data Source
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AI summary
A method comprising a) calcining a silica support at temperature in the range of from about 100 °C to about 500 °C to form a precalcined silica support; b) contacting the precalcined silica support with a titanium alkoxide to form a titanated support; c) subsequent to b), contacting the titanated support with a polyol to form a polyol associated titanated support (PATS); d) contacting at least one of the silica support, pre-calcined silica support, the titanated support, the PATS, or combinations thereof with a chromium-containing compound to form a polymerization catalyst precursor; e) drying the polymerization catalyst precursor to form a dried polymerization catalyst precursor; and f) calcining the dried polymerization catalyst precursor to produce a polymerization catalyst, wherein less than about 0.1 wt.% of a highly reactive volatile organic compound (HRVOC) is emitted during the calcining of the dried polymerization catalyst precursor.