Solid Catalyst for Propylene Polymerization with Nonaromatic Donors
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Solution Overview
Problem
Conventional catalyst systems used in propylene polymerization, such as those based on Ziegler-Natta catalysts, face limitations in achieving high stereoregularity and polymerization activity, particularly in producing polypropylene with high rubber content and economic efficiency.
Innovation Solution
A solid catalyst system is developed by reacting dialkoxymagnesium with a metal halide and organic electron donors, including a nonaromatic alkoxy ester-based internal electron donor, under specific temperature and solvent conditions to enhance stereoregularity and activity, allowing for the production of polypropylene with high rubber content through copolymerization with alpha olefins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional Ziegler-Natta catalyst systems are used, then polymerization activity can be maintained, but stereoregularity and rubber content in block copolymers are insufficient
Solution Approach 1:
The patent changes the chemical parameters of the catalyst system by introducing nonaromatic alkoxy ester-based internal electron donors (specifically compounds with formulas (I) and (II) with specific structural parameters) and optimizing the molar ratios of components. This resolves the contradiction by achieving both high stereoregularity (95% or higher isotactic index) and high polymerization activity (over 50 kg polypropylene/g catalyst) simultaneously through precise parameter optimization of the catalyst composition
Solution Approach 2:
The patent creates a composite catalyst system combining multiple components: dialkoxymagnesium carrier, titanium halide, nonaromatic alkoxy ester-based internal electron donors, and external electron donors. This composite structure allows the catalyst to simultaneously achieve high stereoregularity control and high polymerization activity, as well as enable high rubber content (40-60%) in block copolymers, resolving the trade-off between manufacturing precision and productivity
2Strength
If high rubber content block copolymers are produced, then impact strength is improved, but polymerization activity and economic efficiency decrease
Solution Approach 1:
The patent optimizes the compositional parameters of the catalyst system, specifically using nonaromatic alkoxy ester-based internal electron donors with controlled molecular structures (formulas (I) and (II)) and optimizing the molar ratio of internal to external electron donors. This enables the production of block copolymers with high rubber content (40-60%) while maintaining high polymerization activity (over 50 kg polypropylene/g catalyst), thus improving impact strength without sacrificing productivity
Solution Approach 2:
The patent creates a new catalyst model that copies and improves upon conventional Ziegler-Natta catalysts by replacing traditional internal electron donors with specifically designed nonaromatic alkoxy ester-based compounds. This new catalyst model enables simultaneous achievement of high rubber content for improved impact strength and high polymerization activity for economic efficiency
3Productivity
If aromatic dialkyldiester or aromatic monoalkylmonoester is used as internal electron donor, then catalytic activity increases, but stereoregularity and copolymerization properties are insufficient
Solution Approach 1:
The patent inverts the conventional approach by replacing aromatic internal electron donors with nonaromatic alkoxy ester-based compounds. This inversion leads to unexpected improvement in stereoregularity (isotactic index over 95%) while maintaining high catalytic activity, and additionally enables high copolymerization properties with alpha olefins, resolving the limitations of conventional aromatic donor systems
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 stereoregularity, activity, and hydrogen reactivity, enabling the production of polypropylene with improved physical properties and high yield of block copolymers containing a high rubber content, addressing the limitations of existing catalysts.
Implementation Method 1
reacting dialkoxymagnesium with a metal halide and organic electron donors, including a nonaromatic alkoxy ester-based internal electron donor
Implementation Method 2
copolymerization with alpha olefin when producing a propylene polymer using a Ziegler-Natta catalyst
Data Source
AI summary
The present invention relates to a solid catalyst for propylene polymerization and a method of producing a propylene polymer or copolymer using the solid catalyst for propylene polymerization, and provides a solid catalyst which prepares a dialkoxymagnesium carrier and is formed of a carrier produced through a reaction of the carrier with a metal halide, a titanium halide, an organic electron donor, etc., and a method of producing a propylene polymer or copolymer through copolymerization of propylene-alpha olefin using the solid catalyst, wherein the dialkoxymagnesium carrier has an uniform particle size range of 10 to 100 μm and a spherical particle shape by adjusting injection amounts, injection numbers, and reaction temperatures of metal magnesium, alcohol and a reaction initiator during a reaction process of metal magnesium and alcohol.