Fluorided Solid Oxide Activator-Support for Olefin Polymerization
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Solution Overview
Problem
Current olefin polymerization catalysts lack sufficient surface area and activity, particularly when using metallocene-based systems, which hinders the production of high-quality polyolefins.
Innovation Solution
The development of fluorided solid oxide activator-supports with increased surface area, produced through a process involving calcination and fluoriding, is used in conjunction with transition metal compounds and optional co-catalysts to enhance catalyst activity in olefin polymerization processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional solid oxide supports are used in metallocene-based catalyst systems, then the catalyst structure is simple and easy to manufacture, but the surface area and catalyst activity are insufficient
Solution Approach 1:
The patent applies composite materials by combining solid oxide support with fluorinated compounds to create a fluorided solid oxide activator-support. This composite structure integrates the structural stability of solid oxides with the high surface area and catalytic activity enhancement provided by fluorination, directly resolving the contradiction between simplicity and catalyst activity.
Solution Approach 2:
The patent employs parameter changes by modifying the surface chemistry of the solid oxide support through fluorination treatment. This chemical modification changes the surface area, porosity, and surface charge parameters of the support, thereby enhancing catalyst activity without fundamentally changing the basic catalyst structure.
2Area of stationary object
If the surface area of solid oxide supports is increased through fluorination, then catalyst activity improves, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by performing fluorination treatment on the solid oxide support before catalyst preparation. This pre-treatment establishes the desired surface area and surface properties in advance, simplifying subsequent catalyst formulation steps while achieving the target surface area enhancement.
Solution Approach 2:
The patent replaces mechanical methods of surface area enhancement (such as physical grinding or crushing) with chemical fluorination treatment. This substitution achieves surface area increase through chemical vapor deposition or solution-based fluorination, which is more controlled and less mechanically intensive than physical methods.
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 resulting catalyst compositions exhibit higher surface areas and catalyst activities, leading to improved polymerization outcomes with increased productivity and quality of polyolefins.
Implementation Method 1
contacting the calcined solid oxide with vapor from a fluorine-containing compound to produce a fluorided solid oxide
Implementation Method 2
contacting the calcined solid oxide with vapor comprising a fluorine-containing compound to produce the fluorided solid oxide
Data Source
Figure 1
AI summary
Methods for the vapor phase preparation of fluorided solid oxide activator-supports, using certain calcining temperatures and fluoriding temperatures, are disclosed.