Magnesium Compound Catalyst for Olefin Polymerization
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Solution Overview
Problem
Current methods for producing propylene-based polymers face challenges such as poor catalyst stability, inadequate particle flowability, and increased tackiness, leading to issues like agglomeration and reduced productivity in polymerization processes.
Innovation Solution
A magnesium compound represented by the formula Mg(OC2H5)2−n(OR1)n is developed, where n is between 0 and 0.35, and used as a support for a solid catalyst component in olefin polymerization, enhancing the smoothness and stability of the catalyst, and a method involving metal magnesium, ethanol, and a halogen is employed to produce this compound.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods (supporting magnesium compound on inorganic oxide or dissolving and precipitating) are used to prepare magnesium compound, then catalyst activity can be improved, but the process becomes very complicated and catalyst stability deteriorates
Solution Approach 1:
The invention extracts and eliminates the unnecessary supporting step on inorganic oxide and the dissolving-precipitating steps. By directly reacting metal magnesium with alcohol and halogen in a simplified one-step process, the patent removes complex intermediate steps while maintaining catalyst activity and improving stability.
Solution Approach 2:
The invention segments the catalyst preparation into distinct stages: first preparing the magnesium compound with specific surface properties through controlled reaction of metal magnesium with alcohol and halogen, then separately adding the transition metal compound. This segmentation allows optimization of each stage independently, improving overall catalyst stability.
2Reliability
If magnesium compound is prepared by conventional methods, then catalyst activity can be maintained, but polymer powder surface smoothness becomes inadequate
Solution Approach 1:
The invention changes the preparation parameters of magnesium compound by controlling the type of alcohol used (affecting chain length and branching), the halogen type, temperature, and reaction time. These parameter changes produce magnesium compound particles with optimized surface smoothness (Sd value) while maintaining catalyst activity.
Solution Approach 2:
The invention focuses on optimizing the local surface quality of magnesium compound particles by controlling the reaction conditions to achieve specific surface smoothness characteristics. This local optimization of surface properties improves polymer powder morphology without affecting bulk catalyst activity.
3Temperature
If copolymerizable monomer ratio is increased to lower melting point and improve impact resistance, then low temperature heat sealing property improves, but tackiness increases and blocking resistance deteriorates
Solution Approach 1:
The invention changes the catalyst system parameters (using specific magnesium compound with controlled surface smoothness and specific transition metal compound) to optimize polymerization kinetics. This allows better control over copolymer structure and molecular weight distribution, reducing low molecular weight amorphous components even at higher copolymerizable monomer ratios, thereby lowering melting point while minimizing tackiness.
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 magnesium compound that maintains high activity and stereoregularity, resulting in olefin polymers with improved powder flowability and reduced tackiness, enabling the production of propylene-based random and block copolymers with excellent low-temperature heat sealing and impact resistance properties.
Implementation Method 1
A method involving metal magnesium, ethanol, and a halogen is employed to produce this compound
Implementation Method 2
A magnesium compound represented by the formula Mg(OC2H5)2−n(OR1)n is developed, where n is between 0 and 0.35, and used as a support for a solid catalyst component in olefin polymerization
Implementation Method 3
used as a support for a solid catalyst component in olefin polymerization, enhancing the smoothness and stability of the catalyst
Data Source
AI summary
A magnesium compound represented by the formula (I):Mg(OC2H5)2−n(OR1)n (I)where R1 is CmH2m+1 (where m is an integer of from 3 to 10), and n is a numerical value satisfying 0<n<0.35; a solid catalyst component for olefin polymer using the magnesium compound; a catalyst for olefin polymer; and methods of producing olefin copolymers such as a propylene-based random copolymer and propylene-based block copolymer by using the catalyst for olefin polymer.