Mixed Magnesium Dialkoxide Particulate for Olefin Polymerization
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Solution Overview
Problem
Conventional methods for synthesizing spherical or ellipsoid magnesium diethoxide result in products with low bulk density and insufficient strength, leading to poor catalyst yield and increased costs when used in olefin polymerization, particularly in fluidized beds, prompting the use of less effective magnesium chloride as a catalyst.
Innovation Solution
A method involving a direct solid-liquid reaction between particulate magnesium metal and a mixture of ethyl alcohol and isopropyl alcohol, with a specific molar ratio, to produce a mixed magnesium dialkoxide particulate with a mean particle size of 10-100 µm and bulk density of at least 0.4 g/ml, enhancing the catalyst's strength and polymerization activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spherical or ellipsoid magnesium diethoxide is synthesized by direct reaction between magnesium metal and ethyl alcohol, then the catalyst can be used for olefin polymerization, but the bulk density is low and the breaking strength is insufficient
Solution Approach 1:
The patent uses a composite approach by reacting magnesium metal with a mixture of ethyl alcohol and isopropyl alcohol to produce a mixed magnesium dialkoxide (magnesium diethoxide and magnesium diisopropoxide). This composite material structure allows the product to achieve both high bulk density (≥0.4 g/ml) and sufficient breaking strength (≥0.5 N), resolving the contradiction between manufacturability and reliability.
2Productivity
If magnesium diethoxide with large mean particle size is used, then the catalyst can be prepared, but grinding and micronization during preparation result in poor catalyst yield
Solution Approach 1:
The patent changes the chemical composition parameter by introducing isopropyl alcohol to the reaction mixture, which alters the physical properties of the resulting magnesium dialkoxide. This parameter change enables the product to maintain high bulk density and sufficient strength without requiring extensive grinding and micronization, thereby improving catalyst yield while controlling particle size.
3Productivity
If conventional magnesium diethoxide is used for olefin polymerization, then polymerization can proceed, but the polymerization activity is insufficient compared to mixed magnesium dialkoxide
Solution Approach 1:
The patent employs a composite material strategy by creating a mixed magnesium dialkoxide system containing both magnesium diethoxide and magnesium diisopropoxide. This composite catalyst component achieves approximately 25% higher polymerization activity while maintaining sufficient strength, overcoming the limitation of conventional single-component magnesium diethoxide.
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 increases the polymerization activity by approximately 25% and reduces catalyst breakdown during preparation, leading to higher polyolefin yields and improved catalyst stability, especially in fluidized bed polymerization.
Implementation Method 1
a method for synthesis of a mixed magnesium dialkoxide particulate by direct solid-liquid reaction between particulate magnesium metal with a mean particle size of 50 μm to 500 μm and two alcohols, the two alcohols being ethyl alcohol and isopropyl alcohol
Data Source
AI summary
A mixed magnesium dialkoxide particulate obtained by direct solid-liquid reaction between particulate magnesium metal with a mean particle size of 50 µm to 500 µm and two or more alcohols including ethyl alcohol and at least one C3-6 alcohol, and comprising magnesium diethoxide, wherein the content of alkoxides other than ethoxide is 2.5 to 15 mol% of the total, the mean particle size (D50) is 20 to 100 µm and the bulk density is at least 0.4 g/ml. The mixed magnesium dialkoxide is for use as a catalyst component for polymerization of olefins such as propylene, exhibits high breaking strength, and when used for preparation of a polymerization catalyst, high polymerization activity is exhibited resulting in a high catalyst product yield.