Preparation of catalyst system
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing metallocene catalyst systems for olefin polymerization exhibit low activity and productivity, particularly in the production of high molecular weight polypropylene polymers, and require complex preparation processes with multiple steps.
Innovation Solution
A simplified preparation process for supported catalyst systems using metallocene complexes combined with boron-containing cocatalysts and aluminoxane cocatalysts, involving a single impregnation step and specific ratios of aluminoxane cocatalyst addition, to enhance catalyst activity and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional supported metallocene catalysts are used, then the catalyst can produce polyolefins, but the catalyst activity and productivity are low
Solution Approach 1:
The patent combines multiple co-catalysts (aluminoxane and boron-containing co-catalyst) with the metallocene complex on a single support, creating a multi-component catalytic system that achieves synergistic effects and significantly higher activity compared to conventional single co-catalyst systems
Solution Approach 2:
The catalyst system uses a composite structure comprising a support material with multiple functional components (metallocene, aluminoxane, and boron-containing co-catalyst) distributed throughout, creating a composite catalytic material with enhanced performance properties
2Productivity
If multiple co-catalysts are added to improve catalyst activity, then productivity increases, but the preparation process becomes more complex
Solution Approach 1:
The patent merges the impregnation steps for multiple co-catalysts into a single combined impregnation process, where both aluminoxane and boron-containing co-catalyst are applied simultaneously or in sequence on the same support, reducing the number of separate preparation steps while maintaining high catalyst activity
Solution Approach 2:
The support material serves multiple functions: it provides structural support, facilitates the distribution of multiple co-catalysts, and enables their synergistic interaction, thereby simplifying the overall catalyst structure and preparation process
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 process achieves higher catalyst activity and productivity, enabling the production of high molecular weight propylene homopolymers and copolymers with increased melt temperature and reduced preparation complexity.
Implementation Method 1
treating a porous inorganic support with aluminoxane cocatalyst in a hydrocarbon solvent
Implementation Method 2
combining a metallocene complex with a boron containing cocatalyst and optionally with an aluminoxane cocatalyst
Data Source
AI summary
Improved preparation process for supported catalyst systems, which comprise a specific class of metallocene complexes in combination with a boron containing cocatalyst and an aluminoxane cocatalyst and use of the new, improved catalyst system.