Olefin Polymerization Catalyst Deactivating Agents

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Solution Overview

Problem

Current methods for terminating polymerization reactions in polymerization reactors often result in excessive costs, cleanup, and downtime, and lack efficiency in rapid termination or catalyst reactivity neutralization during normal production.

Innovation Solution

Introducing a catalyst deactivating agent, such as polyethylene glycol, polypropylene glycol, or specific compounds with the formula R1—X1—R3—X2—R2, into the polymerization reactor system to partially or completely terminate the reaction, either within the reactor or downstream, using transition metal-based catalyst systems with olefin monomers and comonomers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If large amounts of water or isopropanol are injected into the polymerization reactor to terminate the polymerization reaction, then the polymerization reaction can be terminated, but excessive cost, clean-up, and downtime are incurred

Engineering Contradiction:

Improvepolymerization reaction terminationVSAvoiddowntime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent changes the chemical parameter of the termination agent from traditional water or isopropanol to organic compounds containing heteroatoms (O, N, S) such as amines, amides, nitriles, isocyanates, and thiols. This parameter change enables effective catalyst deactivation while avoiding the need for extensive water removal and clean-up operations, thereby reducing downtime and operational costs

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention employs inexpensive organic compounds as disposable termination agents that can be easily introduced into the reactor and subsequently removed or deactivated without requiring complex recovery systems. These compounds serve their termination function and are then discarded or processed as simple byproducts, eliminating the need for expensive and time-consuming clean-up procedures associated with water or alcohol termination

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

Engineering Contradiction:

Improvepolymerization reaction terminationVSAvoidclean-up cost

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent changes the chemical parameter of the termination agent from water or isopropanol to organic compounds containing heteroatoms (O, N, S). This parameter change fundamentally alters the compatibility with the polymerization system, eliminating the need for extensive water removal and clean-up operations, thereby reducing both material loss and operational costs

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the potential harm of using organic compounds (which might be expected to require complex separation) into a benefit by selecting compounds that are either already present in the polymerization system or can be easily removed. The termination agents are chosen such that their presence or byproducts do not necessitate expensive clean-up procedures, effectively converting a potential disadvantage into an advantage

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If traditional termination methods are used, then the polymerization reaction can be terminated, but the catalyst reactivity cannot be efficiently neutralized downstream of the reactor during normal polymer production

Engineering Contradiction:

Improvecatalyst reactivity neutralizationVSAvoidnormal polymer production efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent introduces the termination agent into the polymerization reactor during normal operation to preemptively deactivate the catalyst before the polymer slurry leaves the reactor. This preliminary action ensures that catalyst deactivation occurs in-situ under controlled conditions, eliminating the need for downstream neutralization and maintaining continuous production efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention employs organic compounds containing heteroatoms as intermediary substances that mediate between the active catalyst and the polymerization environment. These intermediaries selectively bind to the catalyst active sites, neutralizing reactivity in a controlled manner that does not disrupt the overall polymer production process, allowing for efficient catalyst deactivation without halting production

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method effectively reduces catalyst activity and polymer production rate, minimizing costs and downtime while maintaining control over polymerization reactions, allowing for rapid termination and efficient neutralization of catalyst reactivity.

Implementation Method 1

contacting the transition metal-based catalyst system with the olefin monomer and the optional olefin comonomer under polymerization conditions to produce an olefin polymer

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS9447204B2Methods for terminating olefin polymerizations

Publication Date: 2016.09.20 CHEVRON PHILLIPS CHEMICAL COMPANY LP

AI summary

Catalyst deactivating agents and compositions containing catalyst deactivating agents are disclosed. These catalyst deactivating agents can be used in methods of controlling polymerization reactions, methods of terminating polymerization reactions, methods of operating polymerization reactors, and methods of transitioning between catalyst systems.