Chromium Catalyst Antifouling Co-catalyst for 1-Octene
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Solution Overview
Problem
Current catalyst systems for tetramerizing ethylene to produce 1-octene suffer from fouling issues due to the formation of undesirable polymers, which can reduce reactor efficiency and product selectivity.
Innovation Solution
Incorporating a co-catalyst formed from a reaction product of an organoaluminum compound and an antifouling compound, such as quaternary salts, organic acids, or chlorinated hydrocarbons, into a catalyst system comprising a chromium compound and a ligand, to reduce fouling and maintain or enhance selectivity towards 1-octene production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a catalyst system including chromium is used for tetramerization of ethylene, then 1-octene production is achieved, but fouling occurs due to formation of undesirable polymers
Solution Approach 1:
The patent introduces an organometallic compound as an intermediary substance that mediates between the chromium catalyst and ethylene reactant. This intermediary controls the reaction pathway to favor tetramerization to 1-octene while suppressing polymerization that causes fouling, thus resolving the contradiction between productivity and harmful byproduct formation
Solution Approach 2:
The patent modifies reaction parameters by introducing specific organometallic compounds with controlled ligand structures (Formula I) and adjusting ratios of catalyst components. These parameter changes alter the reaction selectivity to enhance 1-octene formation while reducing unwanted polymerization, thereby addressing the fouling issue
2Productivity
If conventional catalysts are used for tetramerization, then 1-octene is produced, but selectivity is reduced due to formation of other polymer products
Solution Approach 1:
The organometallic compound acts as a selective intermediary that guides the reaction toward the desired tetramerization pathway. Its specific ligand structure (Formula I) creates a controlled coordination environment that enhances selectivity for 1-octene while minimizing formation of other polymer products
Solution Approach 2:
The patent employs ligands with specific local structural characteristics (Formula I) that create a localized reactive environment around the chromium center. This local quality control ensures that only ethylene molecules in specific orientations and positions can react, thereby enhancing selectivity for 1-octene production
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 proposed catalyst system effectively reduces fouling and maintains or improves the selectivity of 1-octene production, compared to systems without the antifouling compound, while minimizing the impact on catalytic activity.
Implementation Method 1
a catalyst comprising a reaction product of a chromium compound and a ligand having the structure according to Formula (II)
Implementation Method 2
a co-catalyst comprising a reaction product of an organoaluminum compound and an antifouling compound
Data Source
AI summary
Catalyst systems suitable for tetramerizing ethylene to form 1-octene may include a catalyst including a reaction product of a chromium compound and a ligand having the structure according to Formula (II). In Formula (II), A and C may be independently chosen from phosphorus, arsenic, antimony, bismuth, and nitrogen; B may be a linking group between A and C; and R1, R2, R3, and R4 may be independently chosen from a (C1-C50) hydrocarbyl or a (C1-C50) heterohydrocarbyl. The catalyst system may include a co-catalyst including a reaction product of an organoaluminum compound and an antifouling compound. The antifouling compound may include one or more quaternary salts; one or more organic acids, organic acid salts, esters, anhydrides, or combinations of these; one or more chlorinated hydrocarbons, chloro-aluminum alkyls, or combinations of these; one or more polyether alcohols; or one or more non-polymeric ethers.