Ziegler-Natta Catalyst Without Internal Donor for Drag Reduction
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Solution Overview
Problem
Current methods for producing ultrahigh molecular weight polyalphaolefins using Ziegler-Natta catalysts often require internal donors and result in lower monomer conversions, limiting the effectiveness of drag reducing polymers in pipelines.
Innovation Solution
A process involving a supported Ziegler-Natta catalyst system without internal donors, using alkyl aluminum-based co-catalysts and specific temperature and time conditions to achieve high molecular weight polyalphaolefins, with polymerization conducted in inert and oxygen-free conditions to achieve conversions greater than 90%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional Ziegler-Natta catalysts with internal donors are used, then catalyst activity is improved, but monomer conversion is limited to below 90%
Solution Approach 1:
The invention removes the internal donor component from the traditional Ziegler-Natta catalyst system. By extracting this element, the catalyst achieves higher monomer conversions (>90%) while maintaining activity, directly resolving the contradiction between conversion efficiency and catalyst system complexity
Solution Approach 2:
The invention changes the chemical composition parameters of the catalyst system by eliminating internal donors and optimizing the TiCl3:AlCl3 ratio. This parameter modification enables the catalyst to achieve superior monomer conversion rates while simplifying the overall catalyst structure
2Reliability
If higher molecular weight polyalphaolefins are produced, then drag reduction efficiency is improved, but processing difficulty increases
Solution Approach 1:
The invention optimizes polymerization parameters including temperature control (-78°C to 30°C range), reaction time (24 hours to 20 days), and catalyst:monomer ratios to produce ultra-high molecular weight polyalphaolefins with intrinsic viscosity ≥10 dL/g. These controlled parameter changes achieve superior drag reduction efficiency while maintaining manageable processing characteristics through precise condition optimization
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 process effectively produces ultrahigh molecular weight polyalphaolefins with intrinsic viscosity ≥10 dL/g, enhancing their use as drag reducing polymers by significantly reducing frictional resistance in pipelines, thereby increasing throughput.
Implementation Method 1
polymerizing alphaolefin monomers using the supported Ziegler-Natta catalyst system without internal donor in presence of co-catalyst
Implementation Method 2
keeping the polymerization mixture of step (i) at temperature in the range of −15° C. to 30° C. for at least 24 hours; and keeping the polymerization mixture of step (ii) at temperature in the range of 20° C. to 35° C. for at least 14 days
Data Source
AI summary
The present invention relates to a process for preparing ultra-high molecular weight polyalphaolefin. The process consists of polymerizing alphaolefin monomers using the catalyst system consisting of supported Ziegler-Natta catalyst without internal donor in presence of co-catalyst based on alkyl aluminums. The resulting ultra-high molecular weight polyalphaolefins having intrinsic viscosity ≥10 dL/g are used as drag reducing polymers for increasing throughput in the pipelines by reducing frictional resistance in turbulent flow.