Chromium Silica Catalyst Calcination via Fluidized Gas Flow
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Solution Overview
Problem
Current methods for producing polymerization catalysts face challenges in enhancing catalyst performance, leading to increased production costs and inefficient process economics.
Innovation Solution
A method involving calcining a catalyst precursor comprising chromium and silica at temperatures between 95°C to 400°C, with controlled gas flow rates and space velocities, to produce high melt index (MI) catalysts (HMCs) with optimized silica-support characteristics and titanium and chromium compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional catalyst preparation methods are used, then production costs are reduced, but catalyst performance and melt index potential are limited
Solution Approach 1:
The patent applies parameter changes by precisely controlling calcination temperature (95-400°C range) and gas flow rates (2.5-30 times settled volume per minute) to optimize catalyst performance. These parameter optimizations enable improved melt index potential and polymerization efficiency while maintaining cost-effective production through controlled atmospheric conditions during calcination
2Reliability
If calcination is performed at higher temperatures to improve catalyst activation, then catalyst activity increases, but energy consumption and production costs increase
Solution Approach 1:
The patent resolves this contradiction by changing the temperature parameter to a lower range (95-400°C) combined with optimized gas flow rates (2.5-30 times settled volume per minute). This parameter combination achieves sufficient catalyst activation and activity while significantly reducing energy consumption compared to conventional high-temperature calcination methods
Solution Approach 2:
The patent employs pneumatic principles by using controlled gas flow through the catalyst bed during calcination. The gas flow rate (2.5-30 times settled volume per minute) creates fluidization and enhances heat and mass transfer, allowing effective catalyst activation at lower temperatures and reducing overall energy requirements
3Manufacturing precision
If gas flow rate is increased to improve heat and mass transfer during calcination, then catalyst uniformity improves, but equipment complexity and operational difficulty increase
Solution Approach 1:
The patent achieves catalyst uniformity by optimizing the gas flow rate parameter to 2.5-30 times the settled volume per minute. This parameter range creates effective fluidization and uniform heat distribution throughout the catalyst bed, ensuring consistent catalyst properties without requiring complex equipment modifications or control systems
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 approach results in catalysts with improved high melt index potential, enhancing polymerization efficiency and reducing production costs by optimizing catalyst performance.
Implementation Method 1
calcining a catalyst precursor comprising chromium and a silica support material at a temperature in the range of from about 95° C. to about 400° C. in a bed fluidized by a gas flowing at a volumetric flow rate from about 2.5 to about 30 times the settled volume of the bed per minute
Implementation Method 2
calcining a catalyst precursor comprising chromium and silica at temperatures between 95°C to 400°C
Data Source
AI summary
A method comprising calcining a catalyst precursor comprising chromium and a silica support material at a temperature in the range of from about 95° C. to about 400° C. in a bed fluidized by a gas flowing at a volumetric flow rate of from about 2.5 to about 30 times the settled volume of the bed per minute to form a calcined catalyst precursor. A method comprising calcining a catalyst precursor comprising chromium and silica at a temperature in the range of from about 95° C. to about 400° C. with a gas flowing through the bed at a gas hourly space velocity of from about 15 to about 200 per hour. A method comprising calcining a catalyst precursor comprising chromium and silica at a temperature in the range of from about 95° C. to about 400° C. with a gas flowing through the bed at a weight hourly space velocity of from about 1.9 to about 240 per hour.