Magnesium Compound Catalyst for Ethylene Polymerization

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Solution Overview

Problem

The existing catalyst systems for ethylene polymerization, which include magnesium compounds, face issues with particle size distribution and flowability, leading to unstable reactor conditions and poor film appearance due to the pulverization of support materials, which increases fine powder content and decreases powder flowability.

Innovation Solution

A magnesium compound is developed by reacting metal magnesium with ethanol and a halogen-containing compound, resulting in a specific particle size distribution and composition that improves the catalyst's performance without compromising activity or hydrogen sensitivity, using a magnesium compound with a particular composition and particle diameter distribution, combined with a titanium compound and organoaluminum components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the support is mechanically pulverized to improve catalyst activity and film appearance, then catalyst activity and film appearance are improved, but fine powder content increases and powder flowability decreases

Engineering Contradiction:

Improvecatalyst activityVSAvoidfine powder content

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The invention changes the particle size parameters of the magnesium compound support by controlling the reaction conditions (temperature 0-70°C, molar ratios of reactants, reaction time) to produce particles with D50 of 4-20 μm and specific size distribution (P < 4.0), eliminating the need for mechanical pulverization while maintaining high catalyst activity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite magnesium compound with specific composition (formula I) containing ethoxide and other alkoxides in controlled ratios, which provides both high catalyst activity and improved particle morphology that prevents fine powder generation during handling

Inventive Principle:

Principle #40Composite materials

2Productivity

If the support is mechanically pulverized to improve catalyst activity, then catalyst activity is improved, but powder flowability decreases

Engineering Contradiction:

Improvecatalyst activityVSAvoidpowder flowability

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The invention optimizes particle size parameters (D50: 4-20 μm, P < 4.0) and surface properties of the magnesium compound through controlled chemical reaction, achieving both high catalyst activity and excellent powder flowability without mechanical pulverization

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates magnesium compound particles with optimized morphology and size distribution that replicate the beneficial effects of pulverized supports while maintaining intact particle structure, thereby ensuring good flowability

Inventive Principle:

Principle #26Copying

3Manufacturing precision

If mechanical pulverization is performed to improve film appearance, then film appearance is improved, but particle size distribution worsens

Engineering Contradiction:

Improvefilm appearanceVSAvoidparticle size distribution

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The invention precisely controls reaction parameters (temperature 0-70°C, molar ratios, reaction time) to produce magnesium compound particles with optimized size distribution (D50: 4-20 μm, P < 4.0), achieving both good film appearance and stable particle size distribution

Inventive Principle:

Principle #35Parameter changes

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 solution provides a catalyst system with enhanced polymer powder performance, improved film appearance, and maintained catalyst activity, achieving better particle size distribution and flowability without the need for pulverization, thus stabilizing the polymerization process.

Implementation Method 1

reacting metal magnesium, ethanol, an alcohol having from 3 to 10 carbon atoms and at least one of a halogen and a halogen-containing compound containing at least 0.0001 gram atom of a halogen atom relative to one gram atom of the metal magnesium at 0 to 70°C

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentEP1873169B1Magnesium compound, solid catalyst component, ethylene polymerization catalyst, and process for producing ethylene polymer

Publication Date: 2014.01.15 IDEMITSU KOSAN CO LTD

Figure 1
Figure 2(A)~2(B)

AI summary

A magnesium compound obtainable by reacting metal magnesium, ethanol, an alcohol having from 3 to 10 carbon atoms and a halogen and/or a halogen-containing compound containing at least 0.0001 gram atom of a halogen atom relative to one gram atom of the metal magnesium at 0 to 70°C, which comprises composition represented by the formula (I), and which has a particle diameter D50 corresponding to 50% of cumulative weight fraction of from 4 to 20 µm and a particle size distribution index (P) of P<4.0: Mg(OC2H5)2-n(OR1)n (I) where n is a numerical value satisfying 0<n<0.35, R1 is CmH2m+1, and m is an integer of from 3 to 10.