Magnesium Alkoxide Precursor Synthesis for Polyolefin Catalyst
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Solution Overview
Problem
Existing methods for synthesizing magnesium alkoxide precursors result in frangible particles with low mechanical strength, leading to fines formation and contamination issues during catalyst synthesis, which affects plant throughput and polymer quality.
Innovation Solution
A method involving reacting magnesium metal with alcohol and titanium tetrachloride at controlled temperatures to produce a precursor with high particle strength, avoiding iodine contamination and using titanium tetrachloride as a magnesium activator to enhance particle morphology and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If iodine is used as a reaction initiator to synthesize magnesium alkoxide, then the synthesis can proceed, but the resulting particles have low mechanical strength and are prone to breakage
Solution Approach 1:
The patent removes iodine from the synthesis system and replaces it with titanium tetrachloride as the reaction initiator. This extraction of the harmful substance (iodine) eliminates the cause of particle fragility while maintaining the synthesis functionality through an alternative initiator that produces stronger particles.
Solution Approach 2:
The patent changes the chemical parameter of the reaction initiator from iodine to titanium tetrachloride. This parameter change fundamentally alters the reaction outcome, producing magnesium alkoxide particles with enhanced mechanical strength and reduced breakage tendency.
2Ease of manufacture
If iodine is used as an activator in magnesium alkoxide synthesis, then the reaction can be initiated, but iodine compounds remain with the precursor and adversely affect catalyst performance
Solution Approach 1:
The patent extracts and removes iodine from the synthesis system entirely, replacing it with titanium tetrachloride. This eliminates the source of harmful iodine compound contamination that would otherwise remain with the precursor and adversely affect catalyst performance.
Solution Approach 2:
The patent converts the potentially harmful role of an initiator into a beneficial process by using titanium tetrachloride, which initiates the reaction without leaving harmful residues. The titanium compounds formed are actually beneficial for catalyst performance rather than harmful like iodine compounds.
3Ease of manufacture
If spherical magnesium alkoxide particles are synthesized using conventional methods, then the particles can be produced, but they do not retain their morphology or particle size during catalyst synthesis
Solution Approach 1:
The patent changes the synthesis parameters by using titanium tetrachloride as the initiator and controlling the reaction temperature and duration. These parameter changes produce particles with improved structural integrity that retain their spherical morphology and size distribution throughout the subsequent catalyst synthesis process.
Solution Approach 2:
The patent creates beforehand stronger, more durable particles through optimized synthesis conditions using titanium tetrachloride. This prior strengthening cushions the particles against breakage during the subsequent catalyst synthesis operations, maintaining their morphology and size stability.
4Productivity
If conventional magnesium alkoxide synthesis is used, then the process can be completed, but the resin produced has low bulk density which hampers plant throughput
Solution Approach 1:
The patent changes the synthesis parameters by using titanium tetrachloride as the initiator and optimizing reaction conditions. These parameter changes produce particles with higher bulk density, which directly improves resin bulk density and thereby increases plant throughput capability.
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 produces a precursor with controlled morphology and high particle strength, reducing fines formation and iodine contamination, thereby improving catalyst performance and plant efficiency by maintaining particle integrity and preventing reactor choking.
Implementation Method 1
reacting predetermined amount of magnesium metal particles with an alcohol at a temperature ranging between 35° C. to 50° C. under agitation to obtain a reaction mixture; adding predetermined amount of titanium tetrachloride to the reaction mixture leading to the evolution of hydrogen
Implementation Method 2
using titanium tetrachloride as a magnesium activator to enhance particle morphology and strength
Implementation Method 3
heating the reaction mixture gradually till the temperature of the mixture reaches to a reflux temperature and refluxing the reaction mixture till the time the evolution of hydrogen from the mixture stops completely
Implementation Method 4
refluxing the reaction mixture
Implementation Method 5
increasing the temperature of the reaction mixture to about 100° C. to remove the excess alcohol in the reaction mixture
Data Source
AI summary
The present invention provides titanium based precursor for polyolefin catalyst with desired morphology and high particle strength. The of preparation of the precursor in accordance with the present invention obviates the use of iodine.