Pre-activated Ziegler-Natta Catalyst Component for Olefin Polymerization
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Solution Overview
Problem
Ziegler and Ziegler-Natta catalysts used in polyolefin production release flammable gases when in contact with water, posing transportation risks due to the presence of active organometallic residues, which are not adequately addressed by existing pre-activation and pre-polymerization processes.
Innovation Solution
A process involving a reaction between a Mg-based compound and a Ti compound, optionally with an electron donor, followed by treatment with an organoaluminum compound and a chlorinated compound, to produce a solid catalyst component with reduced flammable gas release when exposed to water, while maintaining catalyst performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pre-activation or pre-polymerization is performed to enhance catalyst performance, then polymerization activity and morphological stability are improved, but active organometallic residues remain that release flammable gases upon contact with water
Solution Approach 1:
The patent extracts and removes active organometallic residues from the catalyst surface through a specific treatment process involving reaction with water followed by filtration and drying, thereby eliminating the source of flammable gas release while preserving catalyst activity
Solution Approach 2:
The patent introduces an intermediary treatment step where the catalyst is exposed to controlled water vapor or moisture to convert active organometallic bonds into inactive metal hydroxides or oxides, which do not release flammable gases, thus mediating between catalyst performance and safety
2Productivity
If conventional pre-activation with aluminum alkyl compounds is used, then catalyst activity is enhanced, but the catalyst retains high reactivity toward water causing flammable gas release during storage and transportation
Solution Approach 1:
The patent applies preliminary action by performing a controlled water treatment step after pre-activation to convert remaining active organometallic species into stable forms before storage and transportation, ensuring both high catalyst activity and transportation safety
Solution Approach 2:
The patent changes the chemical state parameters of organometallic residues by controlling the water treatment conditions (temperature, humidity, time) to transform highly reactive species into stable forms that maintain catalyst performance while eliminating flammable gas release
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 process significantly reduces the release of flammable gases upon contact with water, enhancing safety during transportation without compromising catalyst activity or requiring changes in operational parameters.
Implementation Method 1
a reaction step carried out at a temperature ranging from 0 to 150°C in which a Mg based compound of formula (MgCl m X 2-m )·nLB is reacted with a Ti compound, having at least a Ti-Cl bond
Implementation Method 2
a reaction step in which the product coming from the preceding step is reacted with an organoaluminum compound
Implementation Method 3
said pre-activated or prepolymerized catalyst having reduced release of flammable gases in contact with water
Data Source
AI summary
A process for the manufacture of pre-activated or pre-polymerized catalysts for the polymerization of olefins is disclosed. In particular, the present disclosure relates to a process for the preparation of pre-activated or pre-polymerized catalysts comprising a solid catalyst component comprising Ti, Mg, halogen said pre-activated catalyst having reduced release of flammable gases in contact with water.