Propylene Polymerization Catalyst Using Novel Electron Donor
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Solution Overview
Problem
Catalysts for propylene polymerization that use phthalic acid diesters as internal electron donors can contaminate polypropylene products, affecting male fertility and requiring the development of alternative catalysts with improved performance and stereospecificity.
Innovation Solution
A catalyst system for propylene polymerization comprising activated magnesium halide, a titanium compound with a Ti-halogen bond, and a novel internal electron donor compound selected from specific sulfonamide benzoate structures, which are synthesized through a multi-step process involving 2-aminobenzoate compounds and base reactions, providing high activity and stereospecificity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phthalic acid diesters are used as internal electron donors in Ziegler-Natta catalysts, then catalyst activity and stereospecificity are improved, but residual phthalate esters contaminate polypropylene products and affect male fertility
Solution Approach 1:
The patent removes the harmful phthalic acid diester component from the catalyst system while retaining the essential electron-donating function through alternative compounds (cyclic carboxylic acid esters, carbonate esters, or carbamate esters). This extraction of the harmful substance while preserving the beneficial function resolves the contradiction between catalyst performance and product contamination.
Solution Approach 2:
The patent employs electron donor compounds with specific structural characteristics (cyclic esters, carbonate esters, carbamate esters) that are designed to be less persistent and less harmful than phthalates. These alternative compounds achieve the necessary catalytic function while being safer for the final polymer product, effectively replacing long-lived harmful substances with shorter-lived safer alternatives.
2Manufacturing precision
If conventional electron donor compounds are used, then catalyst stereospecificity is improved, but the complexity of avoiding phthalate regulations increases manufacturing constraints
Solution Approach 1:
The patent identifies multiple classes of compounds (cyclic carboxylic acid esters, carbonate esters, carbamate esters) that can all serve as effective electron donors. This multi-functionality approach provides versatility in selecting alternative electron donors that meet both stereospecificity requirements and regulatory constraints, resolving the contradiction between manufacturing precision and system flexibility.
Solution Approach 2:
The patent changes the chemical structural parameters of the electron donor compounds by specifying particular molecular weight ranges, structural features (cyclic vs. linear), and functional group types. These parameter changes enable the catalyst system to maintain high stereospecificity while complying with phthalate regulations, effectively adapting the system to new constraints.
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 catalyst system achieves high polymerization activity and excellent stereospecificity, producing polypropylene with high isotacticity and avoiding the use of phthalic acid diesters, thus addressing the contamination issues and regulatory concerns.
Implementation Method 1
a titanium compound supported on the activated magnesium halide containing at least one Ti-halogen bond
Data Source
AI summary
The present invention relates to a catalyst for propylene polymerization, a catalyst system for propylene polymerization and preparation and use thereof. The catalyst for propylene polymerization comprises: an activated magnesium halide, a titanium compound supported on the activated magnesium halide containing at least one Ti-halogen bond, and an internal electron donor compound selected from one or more of compounds having a structure of below Formula (1), wherein R1 and R6 are each independently selected from a C1-C12 straight or branched alkyl, a C3-C15 cycloalkyl or aryl, and R′ is H, a C1-C5 straight or branched alkyl, or phenyl; R2, R3, R4, and R5 are each independently selected from H, halogen, a C1-C12 straight or branched alkyl, a C3-C8 cycloalkyl, a C6-C15 aryl, or arylalkyl. The present invention can provide a catalyst showing high polymerization reaction activity and excellent stereospecificity, by applying a novel type of internal electron donor.