Metallocene Supported Catalyst With Nanosilica Against Leaching
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Solution Overview
Problem
The leaching of metallocene catalysts during olefin polymerization leads to reactor fouling and reduced catalytic activity due to the exposure of catalysts on silica supports, exacerbated by static electricity and fine powder agglomeration.
Innovation Solution
A metallocene supported catalyst is developed with a silica support and nanosilica having a mean particle size of 10 nm to 100 nm, which physically prevents catalyst leaching and selectively deactivates surface catalysts using Si—OH, maintaining high catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the loading amounts of main catalyst and cocatalyst are increased to increase catalytic activity, then catalytic activity is improved, but catalyst leaching occurs and fine powder is generated causing reactor fouling
Solution Approach 1:
A silane coating layer is formed on the surface of the silica support particles, creating a thin film barrier that prevents catalyst leaching while maintaining high catalytic activity. The coating layer acts as a flexible shell that confines the catalyst within the support structure, preventing fine powder generation and reactor fouling even at high catalyst loading amounts.
Solution Approach 2:
The invention uses a composite structure combining silica support particles with a silane coating layer, creating a multi-layered material system. This composite structure integrates the high surface area of silica with the protective and electrostatic properties of the silane coating, achieving both high catalytic activity and prevention of catalyst leaching.
2Object-generated harmful factors
If traditional anti-fouling agents are used to reduce fine powder generation, then reactor fouling is reduced, but catalytic activity is greatly reduced due to catalyst deactivation
Solution Approach 1:
The invention changes the chemical parameters of the support surface by applying a silane coating, which modifies the surface properties to reduce electrostatic charge and fine powder generation without using traditional anti-fouling agents. This parameter change maintains catalyst activity while achieving the anti-fouling effect through controlled surface chemistry rather than catalyst deactivation.
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 catalyst significantly reduces fine powder generation, preventing reactor fouling and improving catalytic activity, thereby enhancing the physical properties of the olefin polymer.
Implementation Method 1
nanosilica disposed on a surface of the silica support... physically prevents catalyst leaching
Implementation Method 2
selectively deactivates surface catalysts, thereby reducing fine powder generation
Data Source
AI summary
Provided are a metallocene supported catalyst capable of greatly reducing generation of fine powder during preparation of olefin polymers while exhibiting excellent catalyst activity, and a method of preparing olefin polymers using the same.