Olefin Oligomerisation Catalyst Dilution Reduces Solids
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Solution Overview
Problem
Existing oligomerization processes face challenges with high solids formation and low reaction rates when using aluminum-containing activators at low concentrations, which is undesirable for commercial operations.
Innovation Solution
Activating the catalyst with a metal-containing activator in the presence of an olefinic compound, followed by dilution with a liquid medium, reduces solids formation and maintains acceptable reaction rates even at low aluminum concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If aluminum-containing activator is used at low concentrations to reduce cost, then activator expense is reduced, but solids formation increases and reaction rate decreases
Solution Approach 1:
The catalyst is activated in advance in a concentrated form where the metal-containing activator is present at higher concentration during the activation step. This preliminary activation creates an active catalyst species that can then function effectively at lower activator concentrations during the subsequent oligomerization reaction, thereby reducing solids formation while maintaining catalytic activity.
Solution Approach 2:
The activation step is separated from the oligomerization step. The metal-containing activator is removed or diluted after the activation function is completed, leaving the activated catalyst to perform oligomerization at low activator concentrations. This extraction of the activator after activation prevents the harmful effects of high activator concentration during the reaction.
2Quantity of substance
If aluminum-containing activator is used at low concentrations to reduce cost, then activator expense is reduced, but reaction rate decreases
Solution Approach 1:
The catalyst is activated in advance in a concentrated form where the metal-containing activator is present at higher concentration during the activation step. This preliminary activation creates an active catalyst species that can then function effectively at lower activator concentrations during the subsequent oligomerization reaction, thereby maintaining high reaction rates while using less expensive low concentrations of activator.
Solution Approach 2:
The catalytic process is divided into two distinct stages: activation stage and oligomerization stage. During the activation stage, high concentrion of metal-containing activator is used to generate active catalyst species. During the oligomerization stage, the activated catalyst operates at low activator concentrations. This segmentation allows optimization of each stage independently.
3Reliability
If catalyst is activated at high metal concentration, then catalyst activation is effective, but subsequent oligomerization requires dilution to reduce solids formation
Solution Approach 1:
The catalyst is activated in advance in a concentrated form where the metal-containing activator is present at higher concentration during the activation step. This preliminary activation creates an active catalyst species that can then function effectively at lower activator concentrations during the subsequent oligomerization reaction, thereby reducing solids formation while maintaining catalytic activity.
Solution Approach 2:
The activated catalyst species acts as an intermediary between the high concentration activation step and the low concentration oligomerization step. The activation process creates a stable active species that can operate effectively even when the original activator is diluted or removed, thus bridging the gap between effective activation and reduced solids formation.
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 allows for oligomerization with reduced solids formation and high catalyst activity, achieving selectivity and efficiency in producing desired olefinic products like hexene and octene, even at low aluminum concentrations below 6 mmol/L.
Implementation Method 1
a mixture of a transition metal and a heteroaromatic ligand, both in a concentration greater than 6 mmol/L, is contacted with a metal containing activator in the presence of an olefinic compound to form an activated catalyst
Data Source
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AI summary
According to the present invention there is provided a process for producing an oligomeric product by the oligomerisation of at least one olefinic compound including: A) providing an activated oligomerisation catalyst comprising the combination of: i) a source of a transition metal; ii) a ligating compound of the formula (R1)m X1 (Y) X2 (R2)n iii) a metal containing activator; and (iv) at least one olefinic compound; B) diluting the activated oligomerisation catalyst of A with an introduced liquid medium; and C) contacting the at least one olefinic compound to be oligomerised with the diluted activated catalyst of B to produce an oligomeric product.