Fluorided Solid Oxide Preparation with pH-Controlled Neutralization
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Solution Overview
Problem
The production of fluorided solid oxides using fluorine compounds like hydrogen fluoride is hazardous due to corrosiveness and emission of harmful gases, posing safety and environmental concerns.
Innovation Solution
A process involving the neutralization of acidic fluorine-containing compounds with inorganic bases to create an aqueous mixture at a pH of at least 4, followed by contacting a solid oxide to produce fluorided solid oxides, reducing emissions and corrosivity, and allowing for larger particle sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hydrogen fluoride or hydrofluoric acid is used to produce fluorided solid oxides, then fluorided solid oxides can be produced, but corrosiveness and harmful gas emissions occur
Solution Approach 1:
The patent converts the harmful acidic fluorine-containing compounds into beneficial fluorided solid oxides by neutralizing them with basic compounds. The harmful acidity is transformed into a useful fluorination process, where the fluorine from the neutralized acid reacts with the solid oxide support to form the desired fluorided catalyst component, eliminating corrosiveness and harmful emissions while maintaining manufacturing capability
Solution Approach 2:
The patent introduces a basic compound (such as zinc oxide, calcium carbonate, or magnesium hydroxide) as an intermediary substance that mediates between the acidic fluorine-containing compound and the solid oxide support. This intermediary neutralizes the acid in situ, preventing direct contact between the corrosive acid and equipment, while still enabling fluorine transfer to the support to form the active fluorided catalyst
2Ease of manufacture
If traditional fluorination methods are used, then fluorided solid oxides are produced, but safety and environmental concerns arise
Solution Approach 1:
The invention transforms the safety and environmental hazards of traditional fluorination methods into advantages by using neutralization chemistry. The harmful acidic conditions are converted into safe neutral or slightly basic conditions (pH ≥ 4), eliminating safety risks associated with handling concentrated HF while maintaining effective fluorination of the solid oxide support
Solution Approach 2:
The patent fundamentally changes the pH parameter of the fluorination process from highly acidic (traditional HF methods) to neutral or slightly basic (pH ≥ 4). This parameter change transforms the process from hazardous to safe, while still achieving the desired fluorided solid oxide product through alternative chemical pathways using basic fluorine-containing compounds
3Area of stationary object
If smaller particle sizes are used in fluorided solid oxides, then surface area increases, but manufacturing complexity and safety risks increase
Solution Approach 1:
The patent converts the safety risks associated with handling fine particles into an advantage by using the neutralization approach. Since the process operates at pH ≥ 4 rather than highly acidic conditions, the handling, mixing, and processing of fine solid oxide particles becomes safer and less complex, as corrosive safety precautions are eliminated while still achieving high surface area fluorided catalysts
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 minimizes hazardous emissions, reduces corrosivity, and enhances catalytic activity while producing fluorided solid oxides with larger particle sizes, improving safety and efficiency.
Implementation Method 1
contacting an acidic fluorine-containing compound and an inorganic base to produce an aqueous mixture having a pH of at least about 4
Implementation Method 2
Catalyst compositions containing these fluorided solid oxides also are provided by the present invention
Data Source
AI summary
Disclosed herein are methods for preparing fluorided solid oxides by contacting an acidic fluorine-containing compound with an inorganic base to form an aqueous mixture having a pH of at least 4, followed by contacting a solid oxide with the aqueous mixture to produce the fluorided solid oxide. Also disclosed are methods for preparing fluorided solid oxides by contacting an acidic fluorine-containing compound with a solid oxide to produce a mixture, followed by contacting the mixture with a inorganic base to produce the fluorided solid oxide at a pH of at least about 4. The fluorided solid oxide can be used as an activator component in a catalyst system for the polymerization of olefins.