Propylene Polymerization Catalyst Feeding Without Pre-Contact

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Solution Overview

Problem

Existing propylene preliminary polymerization processes face challenges in achieving controlled initiation, morphology, and bulk density due to pre-contact of catalyst components with monomers, leading to inefficient heat management and particle formation.

Innovation Solution

A process for propylene preliminary polymerization in a continuous reactor, where a Ziegler-Natta catalyst system with a substituted phenylene aromatic diester as an internal electron donor is fed without pre-contact with the catalyst activator or monomer, using a specific apparatus to maintain high velocity and prevent premature interaction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If pre-contact of catalyst components with monomers is used, then polymerization initiation is simplified, but control over polymerization rate and heat generation deteriorates

Engineering Contradiction:

Improvepolymerization initiationVSAvoidheat generation control

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The catalyst system is segmented into separate components (pro-catalyst and activator) that are introduced into the reactor independently through separate feeding systems. This segmentation allows controlled interaction timing, enabling polymerization initiation while managing heat generation by controlling when and how the components mix and react.

Inventive Principle:

Principle #1Segmentation

2Productivity

If pre-contact of catalyst components with monomers is used, then polymerization starts faster, but fines polymer particles generation increases

Engineering Contradiction:

Improvepolymerization rateVSAvoidfines particles control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The pro-catalyst and activator are prepared separately in advance and introduced into the reactor through controlled feeding systems. This preliminary preparation allows the catalyst components to be in optimal form before contact with monomers, enabling faster polymerization initiation while controlling particle formation and reducing fines generation through regulated interaction conditions.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If pre-contact of catalyst components with monomers is used, then the process is simpler, but morphology of product formed deteriorates

Engineering Contradiction:

Improvefeeding processVSAvoidproduct morphology

Core Design Contradiction:

Device complexityVSShape

Solution Approach 1:

The feeding system acts as an intermediary mechanism that controls the interaction between catalyst components and monomers. By using separate feeding lines and controlled mixing zones, the system manages the complexity of introducing multiple components while ensuring proper morphology development through regulated contact conditions and distribution patterns.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Loss of time

If pre-contact of pro-catalyst with catalyst activator is used, then catalyst activation occurs earlier, but controlled initiation of polymerization deteriorates

Engineering Contradiction:

Improvecatalyst activation timeVSAvoidpolymerization control

Core Design Contradiction:

Loss of timeVSEase of operation

Solution Approach 1:

The catalyst activation process is made dynamic and controllable through separate feeding systems that regulate when and how the pro-catalyst and activator meet. This dynamic control allows the system to optimize activation timing based on process conditions, achieving rapid activation when needed while maintaining control over the polymerization initiation process through adjustable feeding rates and mixing conditions.

Inventive Principle:

Principle #15Dynamics

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 enables more controlled polymerization, reducing fines generation, improving morphology, and increasing bulk density of the polymer product, while maintaining lower polymerization rates and temperatures.

Implementation Method 1

feeding a propylene monomer and a Ziegler-Natta catalyst system of (a) a pro-catalyst having an internal electron donor comprising a substituted phenylene aromatic diester, (b) a catalyst activator

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

Preliminary polymerization is a process step that occurs prior to a polymerization step. It is characterized as occurring under milder process conditions, with lower monomer concentration and/or lower temperature, in order to have a lower polymerization rate

Methodology Applied

Scientific EffectCoordination polymerization:

Implementation Method 3

using a specific apparatus to maintain high velocity and prevent premature interaction

Methodology Applied

Scientific EffectKinetic energy: Inertia

Data Source

PatentUS12319756B2Propylene preliminary polymerization

Publication Date: 2025.06.03 BRASKEM SA

AI summary

A process for propylene preliminary polymerization in liquid phase that occurs in a continuous preliminary polymerization reactor may include feeding a propylene monomer and a Ziegler-Natta catalyst system having (a) a pro-catalyst having an internal electron donor comprising a substituted phenylene aromatic diester, (b) a catalyst activator and optionally (c) an external donor, into the continuous preliminary polymerization reactor, wherein the feeding is carried out without pre-contact of the pro-catalyst with the catalyst activator, and also without pre-contact of the catalyst activator with the propylene monomer before entering the continuous preliminary polymerization reactor.