Fatty Amine Modified Catalyst Composition for Olefin Polymerization
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Solution Overview
Problem
Metallocene catalysts used in olefin polymerization are prone to reactor fouling, leading to disruptions and premature shutdowns, especially in gas and slurry phase processes, and existing fatty amine additives with particulate inorganic materials are time-consuming to prepare and show inconsistent behavior.
Innovation Solution
A catalyst composition modified with a fatty amine substantially free of particulate inorganic material, specifically ethoxylated stearyl amine, is used, which is dried quickly and consistently to minimize agglomerate formation, allowing for continuous olefin polymerization with enhanced reactor operability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fatty amine additives containing particulate inorganic material are used to address reactor fouling, then reactor fouling is reduced, but preparation time increases and behavior becomes inconsistent
Solution Approach 1:
The invention extracts and removes the particulate inorganic material from the fatty amine additive system, using only the organic fatty amine component. This eliminates the preparation time issues and inconsistent behavior associated with particulate materials while retaining the antifouling benefits of the fatty amine.
Solution Approach 2:
The invention changes the physical state parameter of the additive from a particulate suspension to a pure organic liquid or soluble form. This parameter change eliminates drying time requirements and agglomeration issues while maintaining the chemical functionality of the fatty amine for reducing reactor fouling.
2Ease of operation
If fatty amine/silica compositions are used to improve handling qualities, then handling is improved, but agglomerate formation occurs and drying becomes difficult
Solution Approach 1:
The invention removes the silica particulate component that causes agglomeration and drying difficulties, retaining only the fatty amine which provides adequate handling qualities without the manufacturing problems associated with particulate materials.
Solution Approach 2:
The invention uses a homogeneous organic fatty amine compound without particulate contaminants, eliminating the heterogeneity that causes agglomeration. The pure organic nature of the fatty amine ensures uniform distribution and easy processing without forming difficult-to-dry agglomerates.
3Productivity
If metallocene catalysts are used to achieve high polymerization activity, then productivity increases, but reactor fouling increases
Solution Approach 1:
The invention introduces the fatty amine as an intermediary substance between the metallocene catalyst and the reactor walls. The fatty amine adsorbs onto surfaces and prevents polymer buildup, allowing high-activity metallocene catalysts to operate without causing fouling problems.
Solution Approach 2:
The invention changes the surface properties of the reactor and catalyst particles by introducing the fatty amine, which modifies the interfacial characteristics to prevent polymer adhesion. This allows high-productivity catalysts to maintain their activity without generating fouling issues.
Data Source
AI summary
Polymerization catalyst compositions are provided as are methods of their preparation. The compositions comprise fatty amines and find advantageous use in olefin polymerization processes. The catalyst composition comprises at least one supported polymerization catalyst wherein the catalyst composition is modified with at least one fatty amine wherein the fatty amine is substantially free of particulate inorganic material.