Olefin Polymerization Catalyst Component Morphology Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing Ziegler-Natta catalysts for olefin polymerization face challenges in achieving optimal performance due to interference from precipitating auxiliaries, which affect the morphology and properties of the catalyst components, and there is a need for improved catalysts with specific properties for olefin polymerization.
Innovation Solution
A catalyst component comprising magnesium, titanium, a halogen, and a precipitating auxiliary with a high content of specific configuration isomers (R,R- and/or S,S-isomers) is used, which minimizes the interference of the precipitating auxiliary and results in a catalyst with improved morphology and reduced residual auxiliary content, thereby enhancing the polymerization process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a precipitating auxiliary is used in the preparation of solid catalyst component, then solid particles with good morphology can be obtained, but the prepared solid catalyst component contains residual precipitating auxiliary that interferes with the internal electron donor compound
Solution Approach 1:
The patent extracts the harmful residual precipitating auxiliary from the catalyst component through multiple washing steps using solvents such as hydrocarbons, alcohols, or esters. This removal process eliminates the interference of the precipitating auxiliary on the internal electron donor compound while preserving the beneficial particle morphology achieved during precipitation.
Solution Approach 2:
The patent changes the physical and chemical parameters of the precipitating auxiliary by selecting specific types (carboxylic acids, esters, ketones, ethers, or their combinations) and controlling their content within specific ranges (0.1-5 wt% in the catalyst component). These parameter changes optimize both particle morphology and minimize residual auxiliary interference.
2Reliability
If the content of precipitating auxiliary in catalyst component is increased to improve particle morphology, then better catalyst performance is achieved, but the interference effect of precipitating auxiliary on internal electron donor compound increases
Solution Approach 1:
The patent optimizes the content of precipitating auxiliary within specific ranges (0.1-5 wt% in the catalyst component) to achieve the best balance between particle morphology and minimal interference. This parameter optimization ensures reliable catalyst performance while controlling the harmful effects of residual auxiliary.
Solution Approach 2:
The patent employs extraction processes using appropriate solvents to remove excess precipitating auxiliary from the catalyst component, thereby reducing its interference effect on the internal electron donor compound while maintaining sufficient auxiliary content to preserve particle morphology and catalyst performance.
3Ease of manufacture
If conventional precipitating auxiliaries are used, then solid precipitation is achieved, but the residual auxiliary interferes with the effect of internal electron donor compound on polymerization
Solution Approach 1:
The patent applies extraction processes using solvents such as hydrocarbons, alcohols, or esters to remove residual precipitating auxiliary from the catalyst component. This removal enhances the precision of polymerization control by eliminating interference with the internal electron donor compound, while the precipitation process itself remains straightforward and easy to manufacture.
Solution Approach 2:
The patent changes the parameters of the precipitating auxiliary by selecting specific chemical types and controlling their content within optimized ranges. This ensures easy solid precipitation during manufacturing while minimizing residual auxiliary interference, thereby achieving both ease of manufacture and high manufacturing precision in polymerization control.
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 catalyst component achieves high activity, stereospecificity, and narrow molecular weight distribution of polyolefins, with improved particle morphology and reduced interference from the precipitating auxiliary, leading to enhanced polymerization efficiency.
Implementation Method 1
carrying out solid precipitation, and supporting a titanium-containing active component. In such a method, in the step of precipitating solids, solids with uniform particle size and good morphology can usually be obtained only when a precipitating auxiliary is present
Data Source
AI summary
A catalyst component for olefin polymerization includes magnesium, titanium, a halogen, an internal electron donor compound, and a precipitation aid. The precipitation aid includes a precipitation aid represented by general formula (I). The precipitation aid represented by general formula (I) includes isomers represented by general formula (I-a) and/or (I-b).