Double Metal Cyanide Catalyst Composition for Minimal Residue
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Solution Overview
Problem
The existing double metal cyanide (DMC) catalysts exhibit insufficient catalytic activity, require large amounts, and necessitate a catalyst residue removal process, which hinders the production of high-quality polyether carbonate polyol and reduces productivity.
Innovation Solution
A composition for a double metal cyanide catalyst comprising tert-butanol, a linear or cyclic (C2-C12) aliphatic polyhydric alcohol, and polyalkylene glycol as a complexing agent, along with specific metal salts and complex salts, is used to enhance catalytic activity and minimize catalyst residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional DMC catalyst is used for polyether carbonate polyol preparation, then polymerization reaction can proceed, but catalytic activity is insufficient and large amount of catalyst is required
Solution Approach 1:
The patent modifies the chemical composition parameters of the catalyst system by introducing a specific complexing agent containing tert-butanol and aliphatic polyhydric alcohol in controlled mole ratios (1:0.1 to 1:0.9). This parameter change optimizes the catalyst's interaction with reactants, significantly improving catalytic activity while reducing the required catalyst amount from conventional levels to just 0.01-5 wt% of epoxide compound.
Solution Approach 2:
The invention creates a composite catalyst system combining metal salt (M1Xp), metal cyanide complex salt (M2(CN)q), and specifically designed complexing agent (tert-butanol + aliphatic polyhydric alcohol). This composite structure leverages synergistic effects where the complexing agent modulates the metal centers' activity, achieving high catalytic efficiency with minimal catalyst loading.
2Productivity
If conventional DMC catalyst is used, then polymerization reaction occurs, but catalyst residue remains requiring removal process
Solution Approach 1:
The complexing agent acts as an intermediary that facilitates the catalytic reaction while being easily separable. The tert-butanol and aliphatic polyhydric alcohol form transient complexes with metal centers during reaction, enabling high activity, then can be removed via simple filtration or distillation, leaving minimal residue in the final polyether carbonate polyol product.
Solution Approach 2:
The catalyst system is designed so that after completing the polymerization function, the catalyst and complexing agent can be easily discarded through filtration or distillation processes. The water-soluble nature of the complexing agent allows for simple aqueous washing to remove catalyst residues, eliminating complex purification steps while maintaining product quality.
3Object-generated harmful factors
If catalyst amount is decreased to reduce residue, then catalyst residue reduces, but polymerization reaction time becomes longer and product quality deteriorates
Solution Approach 1:
By changing the chemical parameters of the catalyst system (adding specific complexing agent at optimized ratios), the catalytic activity per unit catalyst is dramatically increased. This allows using only 0.01-5 wt% catalyst while maintaining short reaction times and high product quality, reversing the traditional trade-off where less catalyst meant worse performance.
Solution Approach 2:
The composite catalyst system with complexing agent creates highly active catalytic sites that maximize reaction efficiency at low catalyst loadings. The synergistic interaction between metal salts, cyanide complexes, and the specific organic complexing agent ensures high activity even at 0.01 wt% loading, preventing both excessive residue and poor product quality simultaneously.
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 improved catalyst achieves high-quality polyether carbonate polyol production with minimal catalyst use, eliminating the need for residue removal and enhancing productivity under mild conditions.
Implementation Method 1
tert-butanol; a linear or cyclic (C2-C12) aliphatic polyhydric alcohol, and polyalkylene glycol as a complexing agent
Implementation Method 2
double metal cyanide (DMC) catalyst having excellent catalytic activity in a polymerization reaction of a polyether carbonate polyol
Data Source
AI summary
One aspect of the present invention provides a double metal cyanide catalyst having excellent catalytic activity, and a method for preparing same. In particular, the double metal cyanide catalyst according to one aspect is characterized by being prepared using a complexing agent including tert-butanol, a linear or cyclic (C2-C12) aliphatic polyhydric alcohol, and polyalkylene glycol.