Preparation of catalyst system
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Solution Overview
Problem
Existing metallocene catalyst systems for olefin polymerization suffer from low activity and productivity, particularly in the production of high molecular weight propylene polymers, and require complex preparation processes.
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 usage, to enhance catalyst activity and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple co-catalysts and metallocene compounds are laminated on the carrier in separate steps, then catalyst activity is improved, but preparation process complexity increases
Solution Approach 1:
The patent combines multiple catalyst components (metallocene compound, first co-catalyst, second co-catalyst) into a single impregnation step rather than separate lamination steps. The support material is simultaneously impregnated with all three components in one operation, reducing preparation complexity while maintaining the synergistic effects of the combined catalyst system.
Solution Approach 2:
The support material serves multiple functions: it acts as the carrier for the catalyst components and simultaneously serves as the substrate for single-step impregnation of all catalyst components. This multi-functional approach simplifies the preparation process while ensuring proper distribution of all catalyst components.
2Ease of manufacture
If conventional supported metallocene catalysts are used, then preparation is simpler, but catalyst activity and productivity are low
Solution Approach 1:
The patent creates a composite catalyst system where the support material is impregnated with a combination of metallocene compound, first co-catalyst (aluminoxane), and second co-catalyst (boron-containing compound). This composite structure integrates multiple functional components into a single catalyst system that achieves high activity while maintaining preparation simplicity through single-step impregnation.
Solution Approach 2:
The patent optimizes the ratios and amounts of different catalyst components during impregnation, specifically controlling the amount of aluminoxane and boron-containing co-catalyst relative to the metallocene compound. These parameter changes in composition enable high catalyst activity and productivity while using a simplified single-step preparation method.
3Productivity
If aluminoxane and boron-containing co-catalysts are used in specific ratios, then productivity and molecular weight control are improved, but process precision requirements increase
Solution Approach 1:
The patent pre-calculates and specifies optimal ratios of aluminoxane to boron-containing co-catalyst (e.g., 2:1 to 10:1) and their amounts relative to the metallocene compound before the impregnation process. By establishing these ratios in advance, the method enables high productivity and molecular weight control while reducing the precision burden during actual manufacturing, as the optimal composition is predetermined.
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 process achieves high activity and productivity, enabling the production of high molecular weight propylene homopolymers and copolymers with increased melt temperature, while reducing the number of preparation steps and improving flexibility in polymer design.
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 in a hydrocarbon solvent
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.