Lanthanide Pro-Catalyst for Ultra-High Molecular Weight Polyolefins
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Solution Overview
Problem
Existing catalysts for polymerizing olefins struggle with achieving ultra-high molecular weight polyolefins, particularly in the range of 1 million to 6 million g/mol, due to uncontrollable reaction kinetics and fouling of polymerization units, leading to increased operational costs and difficulties in regulating molecular weight.
Innovation Solution
A transition metal-based pro-catalyst represented by Formula I, formed by reacting an aromatic diamine with substituted salicylaldehyde to create a Schiff base imine ligand, which is then chelated with a transition metal halide, offering improved reaction kinetic control and preventing fouling, suitable for both homogeneous and heterogeneous polymerization processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing catalysts are used for polymerizing olefins, then polymerization reaction occurs, but uncontrollable reaction kinetics lead to inability to regulate molecular weight in the range of 1 million to 6 million g/mol
Solution Approach 1:
The patent modifies the ligand structure parameters by introducing specific substituents (R1, R2, R3, R4) at defined positions on the aromatic ring, and changes the metal center from common transition metals to lanthanide metals. These parameter changes in catalyst composition enable precise control over reaction kinetics, allowing regulation of molecular weight in the target range of 1-6 million g/mol while maintaining reliable and controllable polymerization reactions.
2Productivity
If existing catalysts are used for polymerization, then polyolefins are produced, but fouling of polymerization units occurs leading to increased operational costs
Solution Approach 1:
The patent changes the fundamental parameters of the catalyst system by employing lanthanide metals (such as neodymium, praseodymium, or samarium) coordinated with specially designed ligands containing electron-donating groups. This parameter change in metal identity and ligand electronics modifies the polymerization mechanism to produce less fouling-prone polymer products, enabling continuous production with reduced reactor fouling and lower operational costs while maintaining high productivity.
3Manufacturing precision
If conventional catalysts are used, then polymerization proceeds, but difficulty arises in achieving dis-entangled ultra-high molecular weight polyolefins with controlled properties
Solution Approach 1:
The patent employs parameter changes by selecting specific lanthanide metals with defined ionic radii and coordination preferences, and pairing them with ligands having specific substituent patterns (R1-R4 groups at designated positions). These parameter changes in catalyst composition enable precise control over polymer chain entanglement and molecular weight distribution, producing dis-entangled ultra-high molecular weight polyolefins with controlled properties despite the increased complexity of the catalyst structure.
4Ease of operation
If existing catalyst systems are employed, then olefin polymerization occurs, but inability to prevent fouling leads to increased operational costs
Solution Approach 1:
The patent changes the operational parameters by using lanthanide-based catalysts that inherently produce polymer products with reduced fouling characteristics. This parameter change in catalyst chemistry translates to easier operation with lower fouling rates, reduced cleaning frequency, and decreased operational costs, making the polymerization process more economically viable while maintaining high productivity.
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 transition metal-based pro-catalyst effectively produces dis-entangled ultra-high molecular weight polyolefins with controlled molecular weight, reduced operational costs, and prevents reactor fouling, achieving desired properties such as high crystallinity and fibrous morphology.
Implementation Method 1
reacting aromatic diamine of Formula (II) and at least one substituted salicylaldehyde of Formula (IIIa/IIIb) to obtain a Schiff base imine ligand of Formula (IV)
Implementation Method 2
which is then chelated with a transition metal halide
Data Source
AI summary
The present disclosure relates to a transition metal based pro-catalyst represented by Formula I: wherein, the substituents have the meaning as defined in the specification. The present disclosure also relates to a process for preparing the transition metal based pro-catalyst represented by Formula I and the catalyst composition obtained therefrom. Further, the present disclosure relates to a process for polymerizing olefins by employing the catalyst composition comprising the transition metal based pro-catalyst represented by Formula I.