Magnesium Complex Catalyst Solutions Viscosity Reduction
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Solution Overview
Problem
Existing methods for producing supported Ziegler-Natta catalysts result in low product concentration and high viscosity solutions, making them difficult to handle and store stably.
Innovation Solution
Reacting magnesium alcoholates with carboxylic acid halides in hydrocarbon-based solvents to achieve a magnesium concentration of at least 0.9 mmol/g with a molar ratio of carboxylic acid halide to magnesium of at least 0.84:1, using dicarboxylic acid dichlorides, which significantly reduces solution viscosity to less than 500 mPas, allowing for easier handling and longer shelf life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnesium alkoxides are used to produce supported Ziegler-Natta catalysts, then the catalyst can be formed, but the solution viscosity becomes too high for easy handling
Solution Approach 1:
The patent changes the chemical composition parameters by introducing carboxylic acid halides to react with magnesium alkoxides, forming magnesium complexes with carboxylic acid residues. This chemical parameter change transforms the system from high-viscosity magnesium alkoxide solutions to low-viscosity magnesium complex solutions, enabling easy handling while maintaining catalyst formation capability
Solution Approach 2:
The patent creates composite magnesium complexes containing both alkoxide residues and carboxylic acid residues coordinated to magnesium. This composite structure combines the catalytic activity of magnesium alkoxides with the low viscosity properties of carboxylic acid derivatives, resolving the contradiction between catalyst formation and handling ease
2Productivity
If the magnesium concentration in the solution is increased, then the product concentration improves, but the viscosity increases making the solution difficult to pump
Solution Approach 1:
The patent achieves high magnesium concentrations (at least 0.9 mmol/g, preferably at least 1.0 mmol/g) while maintaining low viscosity (less than 500 mPas, preferably less than 100 mPas) by changing the chemical nature of dissolved species from simple magnesium alkoxides to magnesium complexes with carboxylic acid residues. This parameter change allows simultaneous achievement of high productivity and good pumpability
3Reliability
If the solution is stored for extended periods, then the shelf life should be longer, but high viscosity solutions tend to precipitate and become unstable
Solution Approach 1:
The patent changes the molecular structure parameters by forming magnesium complexes with carboxylic acid residues, which have different intermolecular interaction characteristics compared to magnesium alkoxides. This parameter change prevents aggregation and precipitation over time, ensuring storage stability throughout the shelf life period (at least 4 weeks at 30°C)
Solution Approach 2:
The patent uses carboxylic acid halides (particularly dicarboxylic acid dichlorides like phthaloyl dichloride) as transient reagents that react with magnesium alkoxides to form stable complexes. The carboxylic acid halide serves as a temporary intermediate that transforms the system into a stable, long-lasting product, effectively extending shelf life
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 process increases product concentration without increasing viscosity, resulting in low-viscosity, storage-stable solutions that are easy to pump and maintain stability for up to 4 weeks at 30°C.
Implementation Method 1
solutions containing magnesium alcoholate are reacted in a hydrocarbon-based solvent or solvent mixture with one or more carboxylic acid halides
Data Source
Figure 1
AI summary
The invention relates to low-viscosity, concentrated complex solutions containing magnesium, which are produced by reacting a magnesium alkoxide with a carboxylic acid halogenide in a hydrocarbon-based solvent, and to a method for producing the same.