Catalyst Support via Modified Spray Cooling
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Solution Overview
Problem
Existing methods for producing catalyst supports for Ziegler-Natta (ZN) 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 an inorganic compound like magnesium chloride in alcohol with an additive under mild conditions (below 100°C and 5 bar pressure), followed by atomization and precipitation in a non-solvent liquid at low temperature, to produce spherical catalyst supports with improved mechanical strength and solubility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If Spray-Drying technique is used to produce spherical particles, then spherical shape is achieved, but particles become fragile with poor mechanical strength
Solution Approach 1:
The invention changes the temperature parameter from high temperature evaporation (Spray-Drying) to low temperature precipitation (below 100°C, typically -30°C to 0°C). This parameter change transforms the particle formation mechanism from solvent evaporation to cold precipitation, producing particles with dense structure and high mechanical strength while maintaining spherical shape
Solution Approach 2:
The invention utilizes phase transition of the solvent from liquid to solid state through cooling. The molten mixture or solution is sprayed and contacts cold inert gas or liquid, causing rapid cooling and solidification. This phase transition mechanism creates particles with superior mechanical properties compared to evaporation-based methods
2Shape
If Spray-Drying technique is used with high temperature evaporation, then spherical particles are formed, but energy consumption increases
Solution Approach 1:
The invention inverts the temperature parameter from high temperature (evaporation) to low temperature (precipitation). Instead of heating to evaporate solvent, the process uses cooling to precipitate the solid component, dramatically reducing energy consumption while still producing spherical particles through the atomization and rapid cooling mechanism
3Shape
If Spray-Cooling technique is used with molten state mixture, then spherical particles are obtained, but process complexity increases due to multiple control parameters
Solution Approach 1:
The invention combines the atomization function and cooling function into a single integrated step. The molten mixture or solution is sprayed directly into cold inert gas or liquid, where atomization and rapid cooling occur simultaneously. This merging of functions simplifies the process compared to separate atomization and cooling stages, reducing the number of independent control parameters
4Productivity
If rapid removal of alcohol is performed in Spray-Drying, then particle formation occurs, but hollow fragile particles are formed with poor mechanical strength
Solution Approach 1:
The invention inverts the solvent removal approach: instead of rapidly evaporating solvent at high temperature (Spray-Drying), it uses rapid cooling at low temperature to precipitate the solid component. This inversion of the temperature approach prevents hollow particle formation and produces dense, mechanically strong particles while maintaining high productivity through rapid nucleation and growth
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 reduces energy consumption, simplifies the process, and produces catalyst supports with unique DSC profiles and X-ray diffraction patterns, demonstrating enhanced activity for olefin polymerization with improved mechanical strength and reduced solvent content.
Implementation Method 1
dissolving an inorganic compound like magnesium chloride in alcohol
Implementation Method 2
followed by atomization and precipitation in a non-solvent liquid
Implementation Method 3
contacting the droplets with a non-solvent liquid at low temperature to precipitate spherical particles
Implementation Method 4
precipitation in a non-solvent liquid at low temperature, to produce spherical catalyst supports
Data Source
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 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 order to produce an active catalyst for olefin polymerization.