Solid Metallocene Catalyst Preparation Process
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Solution Overview
Problem
Current methods for preparing metallocene catalyst systems for olefin polymerization do not achieve optimal catalyst activity, limiting the production of high-quality olefin-based polymers.
Innovation Solution
A process involving the contacting of an activator-support, a solid metallocene compound, and an organoaluminum compound, either sequentially or simultaneously, to form a catalyst composition that enhances catalytic activity by forming a precontacted mixture and subsequent interaction, which results in improved polymerization outcomes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a solution of metallocene compound is used in catalyst preparation, then the process is easier to handle, but the catalyst activity is lower
Solution Approach 1:
The invention changes the physical state parameter of the metallocene compound from dissolved (solution) to solid form. This parameter change resolves the contradiction by achieving higher catalyst activity through the solid form while maintaining process feasibility through controlled handling procedures for the solid material
Solution Approach 2:
The invention applies preliminary action by pre-contacting the solid metallocene compound with the activator support before adding the organometallic compound. This sequential preparation approach allows the solid metallocene to be properly positioned and activated, achieving high catalyst activity while maintaining operational control through structured preparation steps
2Productivity
If a solid metallocene compound is used in catalyst preparation, then the catalyst activity increases, but the process complexity increases
Solution Approach 1:
The invention segments the catalyst preparation process into distinct sequential steps: first pre-contacting the solid metallocene with the activator support, then adding the organometallic compound. This segmentation manages process complexity by breaking down the preparation into controlled stages, each with specific objectives and parameters
3Productivity
If the metallocene compound is precontacted with the activator support, then the catalyst activity increases, but the preparation time increases
Solution Approach 1:
The invention applies preliminary action by performing the pre-contacting step between solid metallocene and activator support before adding the organometallic compound. This preliminary arrangement optimizes the catalytic structure formation, achieving higher activity while managing preparation time through efficient sequential processing rather than simultaneous addition
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 described process leads to increased catalyst activity, with improvements ranging from 1% to 200% compared to using a solution of the metallocene compound, resulting in higher yields and better polymer properties under the same polymerization conditions.
Implementation Method 1
contacting an activator-support and a solid metallocene compound for a first period of time to form a precontacted mixture
Implementation Method 2
contacting the precontacted mixture with an organoaluminum compound for a second period of time to produce the catalyst composition
Data Source
AI summary
Methods for preparing metallocene-based catalyst systems containing an activator-support are disclosed. These methods can include contacting a solid metallocene compound, an activator-support, and an organoaluminum compound, resulting in catalyst systems with increased catalytic activity as compared to catalyst systems utilizing a solution of the metallocene compound.