Magnesium-Supported Titanium Catalyst for UHMWPE
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Solution Overview
Problem
Existing methods for producing ultra-high molecular weight polyethylene (UHMEP) result in catalysts with either low polymerization activity or low apparent density, failing to achieve uniform particle size and high apparent density simultaneously.
Innovation Solution
A method involving the reaction of magnesium dichloride with alcohol to form a magnesium compound solution, followed by reaction with titanium tetrachloride and a phthalate compound to create a magnesium-supported titanium catalyst, which is then used for polymerization with an organometallic compound in the absence of oxygen and organic solvents to produce UHMEP with uniform particle size and high apparent density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a catalyst containing magnesium, titanium and silane compound is used, then uniform particle size distribution is achieved, but apparent density is insufficient
Solution Approach 1:
The patent changes the chemical parameters of the catalyst by introducing phthalate compounds (with specific molecular structures containing aromatic rings and ester groups) instead of silane compounds. This parameter change in catalyst composition modifies the polymerization characteristics to produce polyethylene with both uniform particle size distribution and high apparent density (0.94-0.96 g/cm³).
Solution Approach 2:
The patent creates a composite catalyst system combining magnesium dichloride, titanium tetrachloride, and phthalate compounds in specific ratios. This composite catalyst structure leverages the synergistic effects of each component: magnesium provides structural support, titanium enables catalytic activity, and phthalate compounds control polymer morphology, achieving both uniform particle size and high apparent density simultaneously.
2Productivity
If a catalyst with high polymerization activity is used, then productivity is improved, but particle size uniformity and apparent density deteriorate
Solution Approach 1:
The patent optimizes catalyst parameters by using phthalate compounds with specific molecular weights and structures (where R1 and R2 are alkyl groups of 1-10 carbon atoms). This parameter optimization allows the catalyst to maintain high polymerization activity while controlling particle growth, achieving uniform particle size distribution (P90/P10 < 1.5) and high apparent density without sacrificing productivity.
3Ease of manufacture
If conventional catalyst methods are used, then polymerization can proceed, but apparent density remains low and particle size distribution is non-uniform
Solution Approach 1:
The phthalate compounds act as intermediary substances in the catalyst system, mediating between the magnesium and titanium components. These intermediaries control the polymerization mechanism to produce dense polyethylene particles with uniform size distribution, while the catalyst remains easily manufacturable through standard chemical reactions.
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 achieves high polymerization activity and produces UHMEP with uniform particle size and high apparent density, enhancing the productivity and properties of the polymer.
Implementation Method 1
reacting magnesium dichloride with alcohol to prepare a magnesium compound solution
Implementation Method 2
reacting titanium tetrachloride with the magnesium compound solution prepared in the step (1) to prepare a precursor
Implementation Method 3
reacting the precursor with titanium tetrachloride and at least one phthalate compound represented by a following general formula (I) to prepare the catalyst
Implementation Method 4
a magnesium-supported titanium solid catalyst and a preparation method of ultra-high molecular weight polyethylene using the same
Data Source
AI summary
Disclosed is a method for preparing a titanium solid catalyst supported on magnesium dichloride that may be used to prepare ultra-high molecular weight polyethylene having a high apparent density. Performing a polymerization reaction using a solid catalyst containing titanium tetrachloride and a phthalate compound may allow ultra-high molecular weight polyethylene having uniform particle size and high apparent density to be prepared.