Olefin Polymerization Catalyst System Temperature-Gradient Support
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Solution Overview
Problem
Hybrid catalyst systems for olefin polymerization often exhibit low activity and metering issues due to catalyst adhesion in reactor apparatus, limiting their effectiveness and ease of use.
Innovation Solution
A catalyst system is developed by activating a first active catalyst component at a specific temperature and a second active catalyst component at a lower temperature, typically using transition metal compounds like metallocenes and iron complexes, which are then supported on a catalyst system to enhance activity and flow properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hybrid catalyst systems with multiple active catalyst components are used to broaden molecular weight distribution, then polymerization performance is improved, but catalyst activity decreases and metering becomes difficult due to adhesion to reactor walls
Solution Approach 1:
The patent applies segmentation by dividing the catalyst system into multiple discrete active catalyst components (e.g., metallocene and non-metallocene components) that are physically separated on different support particles. This segmentation allows each component to maintain its specific catalytic properties while collectively achieving broad molecular weight distribution, and the physical separation prevents inter-component interactions that would cause adhesion and metering problems.
2Adaptability or versatility
If hybrid catalyst systems with multiple active catalyst components are used to broaden molecular weight distribution, then polymerization performance is improved, but metering becomes difficult due to adhesion to reactor walls
Solution Approach 1:
The patent uses an intermediary approach by introducing a specific support material (such as silica gel or magnesium compounds) that acts as a mediator between the catalyst components and the reactor environment. This support material provides a surface that prevents direct adhesion of the catalyst to metal surfaces, thereby facilitating smooth metering while maintaining the hybrid catalyst's ability to produce broad molecular weight distributions.
3Ease of manufacture
If conventional catalyst activation methods are used, then catalyst preparation is simple, but catalyst activity is low and adhesion problems occur
Solution Approach 1:
The patent applies parameter changes by optimizing the activation conditions (temperature, time, atmosphere) and the chemical composition of the support material to enhance catalyst activity. Specifically, the support material is treated with specific chemicals or heated to controlled temperatures to create surface properties that increase catalyst dispersion and activity, thereby improving productivity while maintaining ease of manufacture through a systematic approach to parameter optimization.
Data Source
AI summary
Process for supportation of a catalyst system comprising at least two different active catalyst components on a support whereinin an earlier supportation step a first active catalyst component is applied to the support at a first predetermined temperature andin a later supportation step a second active catalyst component is applied to the support at a temperature which is at least 20° C. lower than the first predetermined temperature.