Composite Internal-Donor Catalyst for Olefin Copolymerization

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Solution Overview

Problem

Existing olefin polymerization catalysts lack excellent olefin copolymerization ability, polymerization activity, stereospecificity, and hydrogen adjustment sensitivity, particularly when used for ethylene and propylene copolymerization.

Innovation Solution

A catalyst component comprising magnesium, titanium, halogen, and an internal electron donor, specifically compounds A, B, and C, where A is a hydroxybenzoyl compound, B is an ester or ether compound, and C is an alkoxysilane, enhances copolymerization ability while maintaining good polymerization activity and stereospecificity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple internal electron donor compounds are compounded to improve comprehensive catalyst performance, then polymerization activity and stereospecificity are improved, but olefin copolymerization ability becomes insufficient

Engineering Contradiction:

Improvecomprehensive catalyst performanceVSAvoidolefin copolymerization ability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent applies composite materials by combining multiple electron donor compounds (succinate, phthalate, and alkoxysilane) into a single catalyst system. This composite approach creates a catalyst with synergistic effects that simultaneously improves polymerization activity, stereospecificity, and olefin copolymerization ability, resolving the contradiction between comprehensive performance and copolymerization versatility

Inventive Principle:

Principle #40Composite materials

2Productivity

If hydroxybenzoyl compound and phthalate-based compound are used as internal electron donors, then polymerization activity and hydrogen adjustment sensitivity are improved, but olefin copolymerization ability remains insufficient

Engineering Contradiction:

Improvepolymerization activityVSAvoidolefin copolymerization ability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent changes the chemical composition parameters of the electron donor system by introducing alkoxysilane compounds with specific molecular structures and ratios. This parameter modification transforms the catalyst's electronic properties and steric environment, enabling it to maintain high polymerization activity while gaining improved olefin copolymerization ability

Inventive Principle:

Principle #35Parameter changes

3Reliability

If alkoxysilane compound is used as external electron donor to improve hydrogen adjustment sensitivity, then catalyst performance is enhanced, but preparation time is extended

Engineering Contradiction:

Improvehydrogen adjustment sensitivityVSAvoidcatalyst preparation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent merges the functions of internal and external electron donors by incorporating alkoxysilane compounds directly into the internal electron donor system during catalyst preparation. This consolidation eliminates the need for separate external donor addition steps, reducing preparation time while maintaining improved hydrogen adjustment sensitivity

Inventive Principle:

Principle #5Merging (Combining)

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 catalyst component achieves excellent olefin copolymerization ability, polymerization activity, and stereospecificity, with improved polymer particle morphology.

Implementation Method 1

the internal electron donor comprises a compound B and a compound C, wherein the compound B is selected from one or more of an ester compound other than a hydroxybenzoyl compound represented by formula (I) and an ether compound

Methodology Applied

Scientific EffectElectron donation: Catalysis

Implementation Method 2

a titanium compound and an electron donor are loaded onto active magnesium halide to prepare a Ziegler-Natta catalyst

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

the internal electron donor comprises a compound A, a compound B and a compound C; wherein, the compound A is selected from a hydroxybenzoyl compound represented by formula (I)

Methodology Applied

Scientific EffectElectronic interaction: Catalysis

Data Source

PatentUS20250320318A1Olefin polymerization catalyst component, catalyst system, prepolymerization catalyst composition and olefin polymerization method

Publication Date: 2025.10.16 CHINA PETROLEUM & CHEMICAL CORP

AI summary

An olefin polymerization catalyst component, a catalyst system, a prepolymerization catalyst composition and an olefin polymerization method are provided. The catalyst component contains magnesium, titanium, halogen, and an internal electron donor. The internal electron donor includes a compound A, a compound B and a compound C. The compound A is selected from a hydroxybenzoyl compound represented by formula (I), the compound B is selected from one or more of an ester compound other than the compound A and an ether compound, and the compound C is selected from an alkoxysilane represented by formula RnSi(OR6)4-n. A content of the compound A may be zero. The catalyst system contains the catalyst component and a co-catalyst component or a reaction product of the two, or a prepolymerization catalyst composition prepared by further prepolymerization is used for olefin copolymerization.