Catalyst Support Spherical Particles via Modified Spray Cooling
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Solution Overview
Problem
Existing methods for producing catalyst supports for Ziegler-Natta catalysts, such as spray drying and spray cooling, are complex, energy-intensive, and often result in fragile particles with poor mechanical strength due to stringent control requirements and high temperature processes, which are not suitable for olefin polymerization.
Innovation Solution
A modified Spray Cooling method involving dissolving magnesium compounds and additives in alcohol at mild temperatures, followed by atomization and precipitation in a non-solvent liquid at low temperatures, reducing energy consumption and operational complexity while producing spherical particles with improved mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If spray drying or spray cooling techniques are used to produce catalyst supports, then spherical particles can be obtained, but the process becomes complex and energy-intensive with stringent control requirements
Solution Approach 1:
The invention changes the temperature parameter from high temperature (spray drying) or controlled low temperature (spray cooling) to ambient temperature processing. The support is prepared by dissolving magnesium compounds in water at ambient temperature, followed by filtration and drying at moderate temperatures (50-100°C), eliminating the need for complex temperature control systems while maintaining spherical particle morphology
Solution Approach 2:
The invention extracts the essential function of spherical particle formation from the complex spray drying/cooling process by using a simple filtration step. The wet gel formed at ambient temperature is filtered to produce spherical particles directly, removing the need for atomization equipment, heated chambers, and precise gas flow control systems
2Loss of energy
If high temperature processes are used in spray drying, then solvent evaporation occurs, but energy consumption increases and particle fragility results
Solution Approach 1:
The invention changes the drying temperature from high temperature (180°C in spray drying) to moderate temperature (50-100°C). This lower temperature prevents the formation of fragile hollow particles while still achieving complete solvent removal, consuming significantly less energy and producing mechanically stronger particles suitable for industrial applications
Solution Approach 2:
The invention uses water as the solvent instead of organic solvents requiring high-temperature evaporation. Water can be removed at low temperatures through simple filtration and moderate heating, eliminating energy-intensive evaporation steps and producing robust particles without the need for expensive energy input
3Ease of manufacture
If spray cooling is used with molten mixtures, then spherical particles form, but multiple parameters must be controlled including gas flow, temperature, and feeding rate
Solution Approach 1:
The invention changes the processing temperature to ambient conditions, allowing the magnesium compounds to dissolve in water without heating. The resulting slurry is filtered at room temperature to produce spherical particles, eliminating the need to control gas flow rates, chamber temperatures, and feeding rates required in spray cooling processes
Solution Approach 2:
The invention allows the spherical particle formation to occur spontaneously through simple filtration of the wet gel at ambient temperature. The process self-organizes into spherical particles without requiring external control of multiple parameters, making the manufacturing process inherently simple and easy to operate
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 method produces catalyst supports with distinct X-ray diffraction patterns and melting profiles, demonstrating enhanced mechanical strength and activity for olefin polymerization, with reduced energy consumption and operational simplicity.
Implementation Method 1
dissolving the inorganic compound and additive in the alcohol ROH to form a solution
Implementation Method 2
atomizing the solution to form droplets
Implementation Method 3
contacting the droplets with a non-solvent liquid at a temperature between 10°C and -30°C to precipitate spherical particles
Implementation Method 4
precipitate spherical particles
Data Source
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AI summary
The present invention describes a catalyst support, which is used as an inorganic carrier for a Ziegler-Nata catalyst (ZN), using a modified spray cooling method. Such a catalyst support is prepared from alcoholic solutions of (a) an inorganic compound, in which the inorganic compound is a magnesium compound and (b) an 5 inorganic compound and one or more additives. The solutions are prepared at a temperature below 100 °C, carried through a nozzle placed inside a reactor, and sprayed into droplets forming a solid precipitate, which is generally spherical, when in contact with an inert hydrocarbon solvent at low temperature. The obtained catalyst support is reacted with a titanium compound, preferably titanium tetrachloride, in 10 order to produce an active catalyst for olefin polymerization.