Modified Double Metal Cyanide Catalyst for Polyether Polymerization
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Solution Overview
Problem
Double metal cyanide (DMC) catalysts exhibit latency periods before activation and perform sluggishly in high hydroxyl concentrations, making them inefficient for producing low molecular weight polyethers and in semi-batch processes.
Innovation Solution
A method involving a catalyst complex formed by reacting a cyanometallate compound with a M1 metal salt in the presence of a M3 metal or semi-metal compound, which shortens the activation time and improves catalyst performance in high hydroxyl environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If DMC catalysts are used for polymerization, then catalyst residues do not need to be removed, but the catalyst exhibits latency periods before activation and performs sluggishly in high hydroxyl concentrations
Solution Approach 1:
The patent uses a composite catalyst system combining DMC catalyst with a second component metal compound (Groups 3-15 or lanthanide series). This composite catalyst maintains the advantage of not requiring removal while achieving high activity in high hydroxyl concentration environments, resolving the contradiction between ease of manufacture and productivity.
Solution Approach 2:
The patent modifies the catalyst system by changing its chemical composition parameters - adding metal compounds from specific groups (3-15 or lanthanide series) to the DMC catalyst system. This parameter change enables the catalyst to activate quickly and perform efficiently in high hydroxyl concentrations, solving the productivity issue while maintaining the ease of manufacture advantage.
2Loss of time
If a second component metal compound is added to reduce activation time, then catalyst performance improves, but additional equipment for storing and metering is required
Solution Approach 1:
The patent combines the second component metal compound with the DMC catalyst into a single integrated catalyst system. This merging eliminates the need for separate storage and metering equipment for the second component, as it is already incorporated into the catalyst formulation, thus reducing device complexity while maintaining the time-saving benefit.
Solution Approach 2:
The composite catalyst system performs multiple functions simultaneously - it provides rapid activation, maintains high activity in high hydroxyl concentrations, and eliminates the need for additional metering equipment. This multi-functionality resolves the contradiction between reducing activation time and avoiding additional equipment complexity.
3Adaptability or versatility
If DMC catalysts are used in semi-batch processes with low equivalent weight starters, then polymerization can proceed, but the catalyst performs sluggishly due to high hydroxyl group concentrations
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst system by incorporating metal compounds from Groups 3-15 or lanthanide series. This modification enables the catalyst to maintain high activity in the high hydroxyl concentration environment characteristic of semi-batch processes with low equivalent weight starters, resolving the contradiction between process adaptability and productivity.
Solution Approach 2:
The composite catalyst system combines DMC catalyst with additional metal compounds to create a formulation that is specifically adapted for high hydroxyl concentration environments. This composite material maintains the versatility needed for semi-batch processes while achieving high polymerization rates, resolving the contradiction between adaptability and productivity.
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 achieves rapid polymerization and reduces the formation of high molecular weight fractions, allowing for efficient production of polyethers even under challenging conditions.
Implementation Method 1
reacting the cyanometallate compound and M1 metal salt to form a water-insoluble catalyst complex that includes a M1 metal cyanometallate
Implementation Method 2
polymerizing the alkylene oxide onto the hydroxyl-containing starter to produce the polyether in the presence of no more than 0.01 moles of a carbonate precursor per mole of alkylene oxide
Data Source
AI summary
Embodiments relate to a method of producing a modified double metal cyanide complex, a method of producing a monol or polyol that includes providing the modified double metal cyanide complex, an alkylene oxide polymerization process that includes providing the modified double metal cyanide complex, a batch, semi-batch, or continuous manufacturing process that includes providing the modified double metal cyanide complex, and a polyether polyol prepared using the batch, semi-batch, or continuous manufacturing process that includes providing the modified double metal cyanide complex.