Fluorinated Catalyst Supports for Polyolefin Production
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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 catalyst system is developed using a fluorinated support generated by heating a catalyst support and a fluoride donor in a fluidized bed reactor with a specific height-to-diameter ratio, and an aluminoxane compound present in limited amounts, along with strategies to reduce chip formation such as impregnating fluoride sources into the support and using smaller particle sizes.
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 cost increases and economic viability deteriorates
Solution Approach 1:
The patent modifies the catalyst support by introducing fluorine atoms at specific sites, changing the chemical parameters of the support to enhance its ability to activate the catalyst compound. This fluorinated support enables achieving acceptable polymerization activities with significantly reduced amounts of activator, thereby resolving the contradiction between productivity and activator quantity.
2Manufacturing precision
If fluorinated alumina supports are scaled up in production, then fluorine levels in the final product are improved, but filter plugging and chip formation increase
Solution Approach 1:
The patent applies local quality by introducing fluorine atoms at specific, controlled sites on the catalyst support rather than uniformly throughout. This localized fluorination approach, achieved through specific reaction conditions and support modification techniques, allows for high fluorine levels in the final product while minimizing the formation of chips and filter plugging issues that arise from bulk fluorination.
Solution Approach 2:
The patent replaces mechanical mixing and bulk fluorination methods with chemical modification approaches. Instead of mechanically mixing fluorine sources throughout the support material, the invention uses chemical reactions to introduce fluorine at specific sites, thereby achieving precise fluorine levels without the mechanical stress and chip formation associated with bulk processing.
3Productivity
If fluorinated alumina supports are scaled up, then production capacity is improved, but chip formation increases
Solution Approach 1:
The patent changes the chemical parameters of the support by introducing fluorine atoms at specific sites, which modifies the structural integrity and reduces chip formation during scaling up. This chemical modification enables higher production capacity while maintaining lower chip formation rates compared to conventional fluorination 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
This approach increases catalyst productivity by enhancing the transition metal component concentration, reduces filter plugging, and maintains high fluorine levels in the product, facilitating more efficient and scalable polyolefin production.
Implementation Method 1
heating a catalyst support and a fluoride donor compound at a temperature sufficient to decompose the fluoride donor compound
Implementation Method 2
forming a fluorinated support
Implementation Method 3
The mixture is fluidized to form a fluidized bed with a height to diameter ratio of at least about 2.3
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 with a height to diameter ratio of at least about 2.3. The mixture is calcined to decompose the fluoride donor, forming a fluorinated support.