Fluorinated Catalyst Supports via Controlled Fluidization
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Solution Overview
Problem
The commercialization of single site catalysts for polyolefin production is hindered by the high cost and large amounts of activators like methylaluminoxane required, and scaling up fluorinated alumina supports leads to issues with filter plugging, chip formation, and reduced fluorine levels in the final product.
Innovation Solution
A method involving the formation of a fluorinated catalyst support by heating a catalyst support and a fluoride donor in a fluidized bed reactor, maintaining specific gas flow rates and temperatures, and using a reduced amount of aluminoxane, such as 10 mmol or less per gram of support, to enhance catalyst productivity while minimizing chip formation and ensuring uniform fluorine distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large amount of activator such as methylaluminoxane is used to achieve acceptable polymerization activities with single site catalyst systems, then catalyst productivity is improved, but the cost increases substantially and the amount of activator required becomes economically unviable
Solution Approach 1:
A fluorinated support material is introduced as an intermediary between the single site catalyst and the activator. This support material interacts with the activator to modulate its activity, allowing the catalyst system to achieve high polymerization activity with significantly reduced activator amounts. The fluorinated support acts as a mediator that enhances catalyst performance while reducing activator consumption.
Solution Approach 2:
The support material is modified by fluorination, changing its chemical properties and surface characteristics. This parameter change in the support material enables it to interact more effectively with the activator and catalyst, improving polymerization activity while reducing the required activator amount. The fluorination process alters the support's electronic and steric properties to optimize catalyst performance.
2Productivity
If fluorinated alumina supports are scaled up for commercial production, then productivity is improved, but filter plugging and chip formation occur reducing manufacturing reliability
Solution Approach 1:
The fluidization gas velocity is precisely controlled within specific ranges (0.6-1.2 ft/sec for external circulation, 0.3-0.8 ft/sec for internal circulation) to optimize the calcination process. This parameter control prevents excessive particle aggregation and chip formation while ensuring complete fluoride donor decomposition and uniform fluorine distribution, enabling reliable large-scale production.
Solution Approach 2:
The process employs controlled fluidization where gas flow rates are adjusted based on bed conditions to maintain optimal particle suspension and heat transfer. This feedback-controlled fluidization prevents localized overheating and particle agglomeration that lead to chip formation, ensuring consistent product quality at commercial production scales.
3Manufacturing precision
If high fluidization gas flow rates are used during calcination to ensure uniform temperature distribution, then manufacturing precision is improved, but chip formation increases reducing productivity
Solution Approach 1:
The fluidization gas velocity is optimized to specific ranges (0.6-1.2 ft/sec for external circulation, 0.3-0.8 ft/sec for internal circulation) that balance two competing requirements: sufficient gas flow to ensure uniform temperature distribution and complete fluoride donor decomposition, but not so high as to cause excessive particle agitation and chip formation. This precise parameter control achieves both temperature uniformity and particle integrity.
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 increases catalyst productivity by up to 130% by optimizing the transition metal component concentration and reduces chip formation and filter plugging, maintaining high fluorine levels in the final product, thus facilitating more efficient and cost-effective large-scale production.
Implementation Method 1
The mixture is calcined to decompose the fluoride donor, forming a fluorinated support
Implementation Method 2
maintaining a flow rate of a fluidizing gas of about 0.1 ft./sec at less than about 370° C. and greater than about 0.35 ft./sec at temperatures greater than about 370° C.
Implementation Method 3
The mixture is fluidized to form a fluidized bed while maintaining a flow rate of a fluidizing gas of about 0.1 ft./sec at less than about 370° C. and greater than about 0.35 ft./sec at temperatures greater than about 370° C.
Implementation Method 4
The mixture is calcined to decompose the fluoride donor, forming a fluorinated support
Implementation Method 5
maintaining a flow rate of a fluidizing gas of about 0.1 ft./sec at less than about 370° C. and greater than about 0.35 ft./sec at temperatures greater than about 370° C.
Data Source
AI summary
Catalyst systems and methods for making and using the same. A method for making a catalyst support includes forming a mixture of a support material and a fluoride donor. The mixture is added to a fluidized bed reactor. The mixture is fluidized to form a fluidized bed while maintaining a flow rate of a fluidizing gas of about 0.1 ft./sec at less than about 370° C. and greater than about 0.35 ft./sec at temperatures greater than about 370° C. The mixture is calcined to decompose the fluoride donor, forming a fluorinated support.