Nanoparticle-Coated Catalyst Support Flowability
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Solution Overview
Problem
In gas-phase polymerization reactors, the cohesiveness of catalyst particles leads to uneven distribution, causing hot spots and polymer agglomeration, which results in operational issues such as reactor shutdowns and increased costs, and the use of continuity aids can affect catalyst activity and product quality.
Innovation Solution
A method involving the formation of a suspension of catalyst support in a protic liquid with applied shear stress and pH adjustments, followed by the addition of nanoparticles, enhances catalyst flowability and dispersion by reducing inter-particle forces, allowing for stable and uniform catalyst distribution without the need for continuity aids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dry powder catalyst is used, then catalyst activity and product quality are maintained, but catalyst cohesiveness causes uneven distribution and hot spots in the reactor
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of the catalyst support through controlled pH adjustment (from initial pH 4.5-7.5 to pH 8-11, then back to pH 4-7) and applying shear stress (100-5000 kPa) during nanoparticle incorporation. These parameter changes reduce inter-particle forces and improve catalyst flowability, enabling uniform distribution while maintaining catalyst activity.
Solution Approach 2:
The patent creates a composite catalyst support by incorporating nanoparticles (2-200 nm) into the catalyst support matrix. This composite structure, formed through sol-gel reaction and hydrolysis processes, reduces cohesiveness and improves flowability while maintaining the catalytic functionality of the support.
2Measurement precision
If slurry catalyst with inert liquid is used, then accurate feeding measurement is improved, but catalyst distribution becomes uneven due to liquid separation from particles
Solution Approach 1:
The patent extracts and eliminates the inert liquid component from the catalyst feeding system. By developing a dry powder catalyst with improved flowability through nanoparticle modification and pH control, the invention removes the slurry-making step entirely, avoiding the separation issue while maintaining accurate feeding measurement through improved powder flow characteristics.
3Ease of operation
If continuity aid is used to reduce electrostatic force, then catalyst flowability is improved, but catalyst activity is reduced and product quality is affected
Solution Approach 1:
The patent introduces nanoparticles as an intermediary substance that mediates between catalyst particles. These nanoparticles (2-200 nm) act as spacers that reduce inter-particle forces and improve flowability without requiring continuity aids. The nanoparticles are incorporated through sol-gel reaction, forming a composite structure that maintains catalyst activity while improving flow characteristics.
4Productivity
If multiple catalyst feeders are used to maintain high flow rate, then catalyst feeding stability is improved, but investment and operational cost increase
Solution Approach 1:
The patent changes the fundamental parameters of the catalyst support (particle size distribution, surface properties, pH) to inherently improve flowability. This allows a single feeder to handle the catalyst effectively, eliminating the need for multiple feeders while maintaining stable feeding rates. The modified catalyst support achieves better flow characteristics through nanoparticle incorporation and controlled pH treatment.
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
This approach improves catalyst flow and dispersion, preventing hot spots and agglomeration, enabling stable reactor operation and maintaining catalyst activity while reducing operational costs and ensuring product quality.
Implementation Method 1
The cohesiveness of the powder resulting from strong inter-particle forces, such as electrostatic forces, van der Waals forces
Implementation Method 2
applying a shear stress to the suspension of between about 100 kPa and about 5000 kPa
Implementation Method 3
The cohesiveness of the powder resulting from strong inter-particle forces, such as electrostatic forces
Data Source
AI summary
The invention relates to a method of preparing a solid polyolefin catalyst support, comprising: forming a suspension of nanoparticles in a solvent; adding an organic silica precursor to the suspension; adding water to the suspension; adding a sol-gel reaction catalyst to the suspension; mixing the suspension at a shear stress of between about 100 kPa and about 5000 kPa; adding a catalyst support to the suspension; continuing the shear stress on the suspension for about 5 minutes to about 720 minutes; separating a solid from the suspension; and drying the solid.