Hydrogen-Free Catalyst Control for Ultra-High Molecular Weight Polypropylene
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Solution Overview
Problem
Existing methods for producing polypropylene are limited in achieving ultra-high molecular weights and require hydrogen as a molecular weight regulator, which restricts the development of materials with improved mechanical properties and new applications.
Innovation Solution
A method for producing ultra-high molecular weight polypropylene by controlling the ratio of a titanium compound as a main catalyst, an alkyl aluminum compound as a co-catalyst, and a silicon compound as a promoter, along with specific polymerization temperature and pressure, without using hydrogen, followed by a catalyst residue removal process to achieve a viscosity average molecular weight of 1,000,000 g/mol or greater and a particle diameter of 400 μm or less.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If hydrogen is used as a molecular weight regulator to control polypropylene molecular weight, then molecular weight can be regulated, but the molecular weight cannot reach ultra-high levels (1,000,000 g/mol or greater)
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst system by introducing a specific silane compound as external electron donor and adjusting the Ti/Al/Si molar ratio to 1:100:10, which fundamentally alters the polymerization mechanism to enable ultra-high molecular weight polypropylene production without hydrogen regulation
Solution Approach 2:
The silane compound acts as an intermediary substance that modifies the catalyst behavior, enabling the formation of ultra-high molecular weight polypropylene by mediating between the titanium catalyst and propylene monomer, thereby achieving molecular weights exceeding 1,000,000 g/mol
2Productivity
If catalyst residues are present in the produced polypropylene, then production efficiency is maintained, but inorganic content increases which deteriorates product performance
Solution Approach 1:
The patent applies a catalyst residue removal process that extracts and separates inorganic catalyst components from the polypropylene product through washing and filtration operations, reducing inorganic content to below 30 ppm while preserving the ultra-high molecular weight characteristics
Solution Approach 2:
The patent discards the inorganic catalyst residues through washing with water and organic solvents, separating them from the polypropylene product, thereby eliminating the harmful inorganic content while maintaining production efficiency
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 method enables the production of ultra-high molecular weight polypropylene with enhanced mechanical properties, suitable for secondary battery separators and insulating materials, by regulating molecular weight and reducing inorganic content through controlled polymerization and catalyst residue removal.
Implementation Method 1
polymerization is performed by using magnesium chloride as a carrier, titanium chloride containing phthalate, di-ether, and succinate compounds as an internal electron donor as a main catalyst, alkyl aluminum as a co-catalyst, and a silicon compound containing an alkoxy group as a promoter
Data Source
AI summary
The present invention relates to a method for producing an ultra-high molecular weight polypropylene having a viscosity average molecular weight of 1,000,000 g/mol or greater and a low inorganic content of 30 ppm or less. According to the method for producing an ultra-high molecular weight polypropylene of the above disclosure, there is the effect that the molecular weight control for producing an ultra-high molecular weight propylene can be achieved with an input ratio of a main catalyst, a co-catalyst and a promoter even if hydrogen used as a molecular weight regulator in general polymerization conditions is not added.