Rare Earth Catalyst Polymerization for Terminal Hydroxy Polymers
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Solution Overview
Problem
Current methods for manufacturing polymers with hydroxy groups at terminals, such as the Alfol process and CCTP, face low yields and significant by-product formation, particularly terminal alkene and terminal conjugated diene, limiting their efficiency and applicability.
Innovation Solution
A method involving the reaction of hydrocarbons with non-conjugated olefins and conjugated dienes using a rare earth element compound-containing catalyst, followed by oxygen and water or alcohol reactions, to achieve high-yield polymer production with terminal hydroxy groups while minimizing by-product formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the Alfol process is used to produce straight-chain higher alcohol, then the polymer with terminal hydroxy group can be manufactured, but the reaction requires high ethylene pressure (120Kg/cm²) which limits its applicability
Solution Approach 1:
The patent changes the reaction parameters by using a rare earth element compound-containing catalyst system that enables the reaction to proceed at low ethylene pressure (5Kg/cm²) instead of the conventional high pressure (120Kg/cm²), while maintaining the formation of terminal hydroxy groups through the three-step reaction process
Solution Approach 2:
The patent introduces an aluminum compound intermediate as a mediator in the reaction pathway. The rare earth element catalyst facilitates the formation of this intermediate, which then reacts with oxygen and subsequently with water or alcohol to produce the final polymer with terminal hydroxy groups, enabling the process to occur at low pressure
2Stress or pressure
If the CCTP method is used to obtain aluminum compound intermediate under low ethylene pressure, then the reaction conditions are relaxed, but terminal alkene mixes in due to side reactions causing β-hydrogen elimination on the transition metal
Solution Approach 1:
The patent converts the potential harm of β-hydrogen elimination side reactions into a beneficial process by using a rare earth element catalyst that directs the reaction pathway. Instead of forming terminal alkene through β-hydrogen elimination, the catalyst promotes ethylene insertion followed by aluminum alkyl exchange, and the resulting intermediate is then oxidized and hydrolyzed to form terminal hydroxy groups, transforming what would be a harmful side reaction into the desired product formation pathway
Solution Approach 2:
The patent employs a controlled three-step reaction process where each step builds upon the previous one: first forming the aluminum compound intermediate through rare earth element catalyzed ethylene insertion and aluminum alkyl exchange, then oxidizing this intermediate with oxygen, and finally reacting with water or alcohol to produce the terminal hydroxy group. This sequential feedback mechanism ensures high selectivity and suppresses by-product formation
3Productivity
If conventional catalysts are used in the Alfol process, then the reaction can proceed, but the yield is low and significant by-products are formed
Solution Approach 1:
The patent uses a rare earth element compound-containing catalyst as an intermediary that facilitates the formation of a specific aluminum compound intermediate through ethylene insertion and aluminum alkyl exchange. This intermediate then undergoes controlled oxidation with oxygen and subsequent reaction with water or alcohol, ensuring high yield of the desired polymer with terminal hydroxy groups while minimizing by-product formation
Solution Approach 2:
The patent changes the catalytic parameters by employing rare earth element compounds instead of conventional catalysts. This catalytic system, combined with the three-step reaction process (ethylene insertion, oxidation, hydrolysis), achieves high productivity and selectivity, producing the target polymer with terminal hydroxy groups in high yield while suppressing by-product formation
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 the high-yield production of polymers with terminal hydroxy groups, suppressing the formation of by-products like terminal alkene and terminal conjugated diene, thereby enhancing manufacturing efficiency and product quality.
Implementation Method 1
reacting a hydrocarbon containing at least either one of a non-conjugated olefin and a conjugated diene compound with an organic aluminum compound, using a rare earth element compound-containing catalyst
Implementation Method 2
inserting ethylene into an aluminum carbide bond, and imparting long-chain trialkylaluminum
Implementation Method 3
a second reaction step of reacting a first reactant obtained from the first reaction step with oxygen
Implementation Method 4
a third reaction step of reacting a second reactant obtained from the second reaction step with at least either one of water and alcohol
Data Source
Figure 1
AI summary
The present invention provides a method for manufacturing polymer that enables manufacturing in high yield, the objective products i.e. a polymer where a hydroxy group is added to a terminal of either one of a homopolymer of a non-conjugated olefin, a homopolymer of a conjugated diene compound, and a copolymer of a conjugated diene compound and a non-conjugated olefin, while suppressing the formation of by-products. The method for manufacturing a polymer of the present invention is a method for manufacturing a polymer where a hydroxy group is added to a terminal of either one of a homopolymer of a non-conjugated olefin, a homopolymer of a conjugated diene compound, and a copolymer of a conjugated diene compound and a non-conjugated olefin, the method comprising: a first reaction step of reacting a hydrocarbon containing at least either one of the non-conjugated olefin and the conjugated diene compound with an organic aluminum compound, using a rare earth element compound-containing catalyst; a second reaction step of reacting a first reactant obtained from the first reaction step with oxygen; and a third reaction step of reacting a second reactant obtained from the second reaction step with at least either one of water and alcohol.