Olefin Oligomerization Catalyst Aging for Selectivity
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Solution Overview
Problem
Olefin oligomerization catalyst systems often lack selectivity, result in low product yield, produce unacceptable quantities of polymer, and tend to degrade at elevated temperatures, necessitating improvements in preparation methods to enhance productivity, selectivity, and temperature stability.
Innovation Solution
A process involving the formation of a catalyst system by contacting a metal compound with a diphosphino aminyl ligand and a metal alkyl comprising aluminoxane, followed by aging in the substantial absence of an olefin monomer, then contacting with the olefin monomer to reduce polymer formation and enhance oligomer product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the catalyst system is prepared by conventional methods without aging in the substantial absence of olefin monomer, then the preparation process is simpler and faster, but the catalyst produces unacceptable quantities of polymer and has low selectivity
Solution Approach 1:
The patent applies preliminary action by performing an aging step in the substantial absence of olefin monomer before the actual oligomerization reaction. This preliminary treatment of the catalyst system allows the metal compound to interact with the ligand and metal alkyl to form an optimized active species, improving selectivity and reducing polymer formation without adding significant complexity to the overall process
Solution Approach 2:
The patent changes the parameter of olefin monomer concentration during the aging step, maintaining it at levels that prevent polymerization (substantial absence) while allowing catalyst activation. This parameter change enables the catalyst to achieve optimal selectivity for oligomer production over polymer formation
2Productivity
If the catalyst system operates at elevated temperatures, then the reaction rate increases and productivity improves, but the catalyst degrades and selectivity decreases
Solution Approach 1:
The patent changes the physical state or chemical structure of the catalyst through the aging process, creating a more thermally stable active species that can withstand elevated temperatures without degradation. This allows the catalyst to maintain both high activity and selectivity at higher reaction temperatures
Solution Approach 2:
The catalyst system forms a composite structure through the interaction of metal compound, diphosphino aminyl ligand, and metal alkyl during aging. This composite catalyst architecture provides enhanced thermal stability while maintaining high productivity and selectivity
3Quantity of substance
If the catalyst system produces high polymer quantities, then more monomer is consumed, but the oligomer product yield and selectivity decrease
Solution Approach 1:
The aging step changes the catalytic properties of the system by forming a more selective active species that preferentially produces oligomers over polymers. This parameter change in catalyst structure enables high monomer conversion to oligomer products with minimal polymer formation
Solution Approach 2:
The patent converts the potential harm of uncontrolled polymerization into benefit by using controlled aging in the substantial absence of monomer to pre-organize the catalyst structure. This preliminary control prevents harmful polymer formation during the actual reaction while maximizing desirable oligomer production
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 reduces polymer formation, improves selectivity, and enhances temperature stability, leading to increased productivity and cost-effectiveness in the olefin oligomerization process.
Implementation Method 1
contacting a metal compound, a diphosphino aminyl ligand, and a metal alkyl to form a mixture
Implementation Method 2
a metal alkyl comprising an aluminoxane
Data Source
Figure 1
AI summary
This disclosure provides for a process for preparing a catalyst system comprising a) contacting a metal compound, a diphosphino aminyl ligand metal complex, and a metal alkyl for a time period to form a mixture; and b) aging the mixture. The disclosure also provides for olefin oligomerization process comprising: a) contacting i) a metal compound, ii) a diphosphino aminyl ligand, and iii) a metal alkyl to form a mixture; b) aging the mixture; c) contacting the aged mixture with an olefin monomer; and d) forming an olefin oligomer product.