Metallocene Catalyst Precontacting with Borinic Acid
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Solution Overview
Problem
Current metallocene catalyst systems for olefin polymerization require high amounts of expensive methyl aluminoxane to achieve high polymerization activities, making them commercially unviable.
Innovation Solution
Precontacting metallocene compounds with borinic or boronic acids before mixing with acidic activator-supports and organoaluminum cocatalysts enhances catalyst activity, reducing the need for excessive aluminoxane and lowering production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large amounts of methyl aluminoxane are used to achieve high polymerization activities, then the catalytic activity is improved, but the production cost increases significantly
Solution Approach 1:
The metallocene is pre-contacted with borinic acid or boronic acid before being mixed with the acidic activator-support and organoaluminum cocatalyst. This preliminary interaction between the metallocene and boronic acid/borinic acid modifies the catalyst precursor, enabling it to achieve high polymerization activity with reduced amounts of expensive methyl aluminoxane cocatalyst.
Solution Approach 2:
Boronic acid or borinic acid acts as an intermediary substance that facilitates the interaction between the metallocene and the activator system. This intermediary modifies the metallocene in advance, allowing the catalyst to function effectively with lower quantities of the expensive methyl aluminoxane cocatalyst, thus resolving the contradiction between activity and cost.
2Productivity
If large amounts of expensive cocatalysts are used to achieve high polymerization activities, then the productivity is improved, but the manufacturing cost increases
Solution Approach 1:
The metallocene is pre-contacted with borinic acid or boronic acid before being mixed with the acidic activator-support and organoaluminum cocatalyst. This preliminary interaction between the metallocene and boronic acid/borinic acid modifies the catalyst precursor, enabling it to achieve high polymerization activity with reduced amounts of expensive methyl aluminoxane cocatalyst.
Solution Approach 2:
The invention replaces the expensive methyl aluminoxane cocatalyst with a more economical system consisting of boronic acid/borinic acid (used in small amounts as a modifier) combined with acidic activator-support and organoaluminum compounds. This substitution with cheaper materials maintains high catalytic activity while significantly reducing manufacturing costs.
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
This approach increases the productivity of olefin polymerization without requiring large amounts of expensive cocatalysts, resulting in more cost-effective catalyst compositions and improved polymerization activities.
Implementation Method 1
contacting at least one metallocene, at least one borinic acid or boronic acid for a first period of time to form a precontacted mixture
Implementation Method 2
contacting the precontacted mixture with at least one acidic activator-support and at least one organoaluminum compound
Data Source
AI summary
This invention relates to the field of olefin polymerization catalyst compositions, and methods for the polymerization and copolymerization of olefins, typically using a supported catalyst composition. In one aspect, this invention encompasses precontacting a metallocene with a borinic acid or boronic acid prior to contacting this mixture with the acidic activator-support and an organoaluminum compound.