Room-Temperature DMC Catalyst Synthesis for Polyether Polyols
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Solution Overview
Problem
Conventional methods for producing polyether polyols using double metal cyanide (DMC) catalysts are energy-intensive, require high temperatures, and involve lengthy induction periods, making the process costly and inefficient, while also requiring complex chemical treatments for catalyst removal.
Innovation Solution
A room temperature method for synthesizing amorphous DMC catalysts using EDTA as a complexing agent and t-BuOH or PEPO as co-complexing agents, which are easily separable and highly active, reducing energy consumption and simplifying catalyst removal through filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional high-temperature methods are used to produce polyether polyols with DMC catalysts, then the catalyst activity and polymerization efficiency are improved, but energy consumption increases and the induction period lengthens
Solution Approach 1:
The patent changes the temperature parameter from high-temperature conventional methods to room temperature operation. This parameter change enables the DMC catalyst to maintain high activity and polymerization efficiency without requiring excessive energy input, thus resolving the contradiction between productivity and energy consumption
Solution Approach 2:
The patent replaces the thermal energy-driven mechanism with a catalyst-driven mechanism at room temperature. By using the DMC catalyst system with appropriate complexing agents, the reaction proceeds efficiently without relying on high temperature, substituting thermal activation with catalytic activation
2Speed
If conventional high-temperature methods are used for polyether polyol production, then reaction rate improves, but the induction period becomes lengthy and production cost increases
Solution Approach 1:
The patent changes the operating temperature parameter to room temperature, which eliminates the lengthy induction period associated with high-temperature methods. The DMC catalyst system at room temperature achieves rapid reaction initiation and maintains high reaction rates without the time loss of thermal activation phases
3Device complexity
If conventional DMC catalysts are used without complexing agents, then the catalyst structure is simpler, but catalyst activity decreases and crystalline structure reduces effectiveness
Solution Approach 1:
The patent creates a composite catalyst system by combining DMC catalyst with organic complexing agents (such as t-BuOH, PEPO, glyme, or ether). This composite structure enhances catalyst activity and prevents crystallization, improving productivity while maintaining reasonable structural complexity through the synergistic interaction of components
4Reliability
If conventional methods are used for catalyst removal, then complete catalyst elimination is achieved, but complex chemical treatments are required increasing process complexity
Solution Approach 1:
The patent extracts the catalyst from the product mixture through simple filtration based on the insolubility of the DMC catalyst complex in the polyether polyol product. This extraction method achieves complete catalyst elimination without requiring complex chemical treatments, reducing process complexity while maintaining reliable catalyst removal
Solution Approach 2:
The patent uses the insolubility characteristic as an intermediary property to separate the catalyst from the product. The DMC catalyst complex acts as an intermediary that can be easily removed through filtration, simplifying the separation process compared to conventional methods requiring complex chemical treatments
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 enables the production of high-molecular-weight polyether polyols with low unsaturation and varying kinematic viscosity ranges, achieving high yields and reducing production costs by minimizing energy use and simplifying the synthesis and separation process.
Implementation Method 1
DMC complexes are known to catalyze the ring-opening polymerization reactions of epoxides such as ethylene oxide (EO), propylene oxide (PO), butylene oxide (BO), isobutylene oxide (IBO), styrene oxide (SO), and other similar organic oxides
Implementation Method 2
The DMC catalysts of the present invention are especially valuable for producing PEPO of a lower degree of unsaturation, especially over a wide range of kinematic viscosity useful in the polyurethanes (PU) industry. The catalysts are prepared in the presence of a complexing agent such as EDTA, t-BuOH, and PEPO
Implementation Method 3
The DMC catalysts of the present invention are easily separable from the produced PEPO by simple filtration, which obviates the need for centrifugation after the production of PEPO
Data Source
AI summary
The present invention discloses a Double Metal Cyanide (DMC) catalyst(s) useful for the production of polyether polyols (PEPO) and a less energy intensive room temperature method for the synthesis thereof. The catalyst(s) comprises of a DMC complex, an organic complexing agent, i.e., ethylenediaminetetraacetic acid (EDTA) and other co-complexing organic agents, e.g., t-BuOH, PEPO of composition ranging from about 1 to 10 wt %, wherein the average molecular weight of PEPO used ranged from 200 to 1000. A method of preparing a series of DMC catalyst(s) at room temperature with varying compositional ratios of the complexing and co-complexing agents targeting a wide range of PEPO of varying kinematic viscosity range is also disclosed. These DMC catalyst(s) are amorphous, highly active, and easily separable from product PEPO with recyclability/recoverability, making the product PEPO better industrially applicable and DMC catalyst more cost-effective.