Integrated Aluminoxane Production for Catalyst Manufacturing
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Solution Overview
Problem
The production of methylaluminoxane (MAO) for catalysts is costly due to the high expense of its precursor, trimethylaluminum (TMA), and involves challenges such as storage, handling, and disposal of pyrophoric MAO, which has a limited shelf life and generates significant waste streams of toluene and unreacted TMA.
Innovation Solution
Integrating aluminoxane production into catalyst production by recycling solvents and unreacted hydrocarbyl aluminum compounds, allowing for continuous production and reducing the need for fresh solvents and storage of concentrated aluminoxane solutions, thereby minimizing waste and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If concentrated MAO solution is produced and stored, then catalyst functionality is improved, but shelf life is limited and coagulation occurs
Solution Approach 1:
The patent applies preliminary action by producing MAO immediately before catalyst manufacturing operations rather than storing it in advance. The system continuously generates MAO from TMA precursor right before use, eliminating the shelf life limitation and coagulation issues associated with storing concentrated MAO solutions while ensuring fresh, functional catalyst activator is always available.
2Reliability
If MAO is produced and stored in concentrated form, then catalyst performance is enhanced, but special storage and handling measures are required due to pyrophoricity
Solution Approach 1:
The system applies self-service by using the TMA precursor that is already present in the catalyst manufacturing process to generate MAO in situ. The TMA serves dual purposes: as a catalyst component and as the precursor for MAO generation. This eliminates the need for separate storage and handling of pyrophoric MAO while maintaining catalyst performance, as the MAO is generated automatically from the TMA already being used in the process.
3Productivity
If conventional MAO production process is used, then MAO is available for catalyst manufacturing, but significant waste streams of toluene and unreacted TMA are generated
Solution Approach 1:
The patent applies discarding and recovering by capturing and recycling the solvent and unreacted TMA that would otherwise be discarded as waste. The system recovers these materials from the MAO production process and feeds them back into the TMA supply for continued MAO generation, creating a closed-loop system that maintains MAO availability for catalyst manufacturing while minimizing waste generation.
4Duration of action of stationary object
If stabilizers are added to extend shelf life, then MAO stability is improved, but additional expenses are incurred
Solution Approach 1:
The patent eliminates the need for stabilizers by applying preliminary action - generating MAO immediately before use rather than storing it. This approach extends shelf life indefinitely by eliminating storage entirely, avoiding the additional expenses of stabilizers while ensuring the MAO is always fresh and stable when needed for catalyst manufacturing.
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 reduces costs associated with aluminoxane production, minimizes waste, and extends the shelf life of aluminoxane by enabling just-in-time production, eliminating the need for storing large quantities of concentrated solutions and reducing disposal issues.
Implementation Method 1
reacting a hydrocarbyl aluminum compound and an oxygen source in a recycled solvent to produce at least a reaction mixture comprising an aluminoxane
Implementation Method 2
separating the catalyst composition from the recycled solvent in the portion of the reaction mixture
Data Source
Figure 1~3
Figure 4~5
AI summary
Methods for integrating aluminoxane production into catalyst production are disclosed.