Spherical Magnesium Halide Adducts for Uniform Catalyst Site Distribution
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Solution Overview
Problem
Existing magnesium halide-alcohol adducts used in Ziegler-Natta catalysts for olefin polymerization suffer from non-uniform distribution of catalytic active sites, leading to cracking of polymer particles and low polymerization activity, with existing attempts to introduce internal electron donors only partially addressing these issues.
Innovation Solution
A spherical magnesium halide adduct is developed, comprising compounds of formula MgXY, ROH, methanol, and modifying agents like o-hydroxy benzoates, which forms a catalyst component with titanium compounds and internal electron donors, resulting in a catalyst with improved particle morphology and hydrogen sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If magnesium halide-alcohol adducts are used as catalyst supports, then spherical catalyst particles can be obtained, but the catalytic active sites are not uniformly distributed leading to particle cracking
Solution Approach 1:
The patent introduces internal electron donor compounds during the preparation of magnesium chloride-alcohol adduct supports before the catalyst formation step. This preliminary incorporation ensures uniform distribution of electron donors throughout the support structure, which subsequently leads to uniform distribution of catalytic active sites and prevents particle cracking during polymerization
Solution Approach 2:
The patent creates a multi-component composite support system consisting of magnesium chloride, alcohol, and internal electron donor compounds (such as phthalates). This composite structure combines the spherical morphology benefits of magnesium halide-alcohol adducts with the uniform site distribution benefits of electron donor incorporation, resolving the contradiction between shape control and particle stability
2Manufacturing precision
If internal electron donor compounds are introduced in advance during support preparation, then uniform active site distribution is improved, but polymerization activity decreases
Solution Approach 1:
The patent optimizes the concentration parameters of internal electron donor compounds in the magnesium chloride-alcohol adduct support. By precisely controlling the amount and type of electron donor (such as using specific phthalate esters at optimized concentrations), the patent achieves both uniform active site distribution and maintains high polymerization activity, resolving the contradiction between manufacturing precision and productivity
3Productivity
If magnesium halide adducts with high polymerization activity are used, then productivity increases, but particle cracking occurs due to non-uniform active site distribution
Solution Approach 1:
The patent incorporates internal electron donor compounds during the support preparation stage before catalyst formation. This preliminary action ensures that when high polymerization activity is achieved through optimized catalyst composition, the particles maintain structural integrity and spherical morphology without cracking, because the active sites are uniformly distributed from the outset
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 new catalyst exhibits high polymerization activity, excellent hydrogen sensitivity, and forms polymers with good morphology, reducing the occurrence of fine powders and non-spherical particles, while maintaining a regular spatial structure and smooth surface.
Implementation Method 1
the adduct supports react with titanium halides and electron donor compounds to obtain spherical catalysts
Implementation Method 2
a catalyst comprising the catalyst component for olefin polymerization
Data Source
AI summary
A magnesium halide adduct is provided, comprising at least one compound of the formula MgXY, at least one compound of the formula ROH, methanol, at least one modifying agent chosen from DOE and o-hydroxy benzoates, and optionally water. Also provided herein are a catalyst component comprising the magnesium halide adduct, a catalyst for olefin polymerization comprising the catalyst component; the respective processes for preparing the magnesium halide adduct and the catalyst component; use of the magnesium halide adduct for preparing the catalyst component, use of the catalyst component in a catalyst for olefin polymerization and use of the catalyst in olefin polymerization; and a process of olefin polymerization.