Poly Alpha Olefin Oligomerization Process with Isomerization Step
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Solution Overview
Problem
Current processes for producing low viscosity poly alpha olefins using metallocene catalysts result in significant formation of dimers with poor low temperature and volatility properties, and have low throughput and yield due to complex reactor setups and filtration units.
Innovation Solution
A process involving the oligomerization of linear alpha olefins to form vinylidene dimers, which are then isomerized to tri-substituted olefin dimers, and further oligomerized to trimers, using a metallocene catalyst and a heat exchanger for isomerization without additional catalysts, allowing for optional filtration and simpler filtration units, enhancing cost savings and throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallocene catalyst is used for oligomerization to produce low viscosity PAO, then excellent lubricant properties are achieved, but significant amount of dimer is formed with poor low temperature and volatility properties
Solution Approach 1:
The patent divides the oligomerization process into multiple stages with different catalysts. The first stage uses metallocene catalyst to produce dimers with good lubricant properties, while the second stage uses a different catalyst system to convert these dimers into trimers and higher oligomers. This segmentation allows optimization of each stage for its specific purpose, achieving high trimer selectivity while minimizing unwanted dimer accumulation.
Solution Approach 2:
The patent changes key process parameters between stages: switching from metallocene catalyst to a different catalyst system, adjusting temperature and pressure conditions, and modifying monomer-to-catalyst ratios. These parameter changes enable selective promotion of trimer formation while suppressing excessive dimer production, directly addressing the contradiction between lubricant quality and dimer formation.
2Manufacturing precision
If complex reactor setup with cellulosic body feed-type filtration units is used, then product purification is achieved, but throughput is reduced due to slow flow rates
Solution Approach 1:
The patent removes the complex cellulosic body feed-type filtration unit from the process. Instead, it employs a simpler filtration system that achieves adequate product purification without the flow rate limitations of the traditional setup. This extraction of the problematic filtration component directly resolves the contradiction between purification quality and throughput.
Solution Approach 2:
The patent replaces the expensive, complex, and slow cellulosic filtration system with a simpler, more economical filtration approach that is sufficient for the application. This substitution maintains adequate product quality while dramatically improving throughput and reducing capital investment requirements.
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 process achieves higher yields and selectivity of trimers, reduces production costs, and improves the properties of low viscosity poly alpha olefins, such as viscosity index and thermal stability, while simplifying the reactor setup and filtration process.
Implementation Method 1
heating the first reactor effluent to form an isomerized product
Data Source
AI summary
The present disclosure provides processes and apparatus for producing poly alpha olefins. In at least one embodiment, a process to produce a poly alpha olefin includes introducing a first olefin monomer to a first catalyst and an activator in a first reactor to form a first reactor effluent comprising olefin dimers and olefin timers. The process includes heating the first reactor effluent to form an isomerized product and introducing the isomerized product to a filtration unit to form a filtration effluent. The process may include introducing the filtration effluent to a first distillation unit to form a first distillation effluent. The process may include introducing the first distillation effluent to a second distillation unit to form a second distillation effluent. The process includes introducing the first distillation effluent and/or the second distillation effluent to a second catalyst in a second reactor to form a second reactor effluent comprising the olefin timers.