Solid Support for Olefin Procatalyst via Controlled Particle Size
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Solution Overview
Problem
There is a need for a phthalate-free procatalyst in the polymerization of olefins that offers improved productivity and bulk density, as existing catalyst systems often rely on phthalate-based components which are not ideal for industrial applications.
Innovation Solution
A process for preparing a solid support for a procatalyst involves reacting a Grignard compound with a silane compound in a solvent, using a mixing device with varying mixing speeds to achieve a solid support with a particle size of at most 17 μm, followed by activation with electron donors and halogen-containing Ti-compounds to form a procatalyst suitable for olefin polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional catalyst system using phthalate-based components is used, then the catalyst system is simple to prepare, but the productivity and bulk density are insufficient
Solution Approach 1:
The patent changes the particle size parameter of the solid support to at most 17 μm through controlled reaction conditions and mixing speeds, which directly improves productivity and bulk density while maintaining ease of manufacture through optimized preparation parameters
Solution Approach 2:
The patent creates a composite catalyst system combining a solid support with specific particle size, a procatalyst, and optional co-catalyst and external electron donors, replacing conventional phthalate-based systems to achieve superior performance while remaining manufacturable
2Quantity of substance
If a conventional catalyst system using phthalate-based components is used, then the catalyst system is simple to prepare, but the bulk density is insufficient
Solution Approach 1:
The patent optimizes the particle size parameter of the solid support to at most 17 μm through controlled reaction conditions, which directly increases bulk density while maintaining ease of manufacture through standardized preparation procedures
Solution Approach 2:
The solid support exhibits porous characteristics that enhance bulk density while maintaining ease of preparation through conventional chemical reaction methods, achieving both high density and manufacturability
3Productivity
If the solid support particle size is reduced to at most 17 μm, then the productivity and bulk density are improved, but the mixing and reaction control becomes more difficult
Solution Approach 1:
The patent employs dynamic mixing control by varying the mixing speed during the reaction process, initially using higher speeds for rapid mixing and then reducing speeds for controlled reaction, which enables production of ultrafine particles at most 17 μm while managing mixing complexity
Solution Approach 2:
The patent uses periodic mixing action with varying speeds during the reaction process to achieve uniform particle size distribution at most 17 μm, improving productivity while simplifying the overall mixing control strategy through structured periodic operation
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 resulting procatalyst exhibits enhanced production rate and bulk density, along with a narrow molecular weight distribution, effectively addressing the need for a phthalate-free catalyst system with improved performance.
Implementation Method 1
reacting a Grignard compound with a silane compound in a solvent
Implementation Method 2
mixing the resulting mixture with a mixing device and at a certain mixing speed
Implementation Method 3
activation with electron donors and halogen-containing Ti-compounds to form a procatalyst suitable for olefin polymerization
Data Source
AI summary
The invention relates to a process for preparing a solid support for a procatalyst suitable for preparing a catalyst composition for olefin polymerization, said process for preparing said solid support comprising reacting a compound R4zMgX42-z with a silane compound Si(OR5)4-n(R6)n in a solvent and mixing the resulting mixture with a mixing device and at a certain mixing speed in order to give a solid support Mg(OR1)xX12-x said solid support obtained having an average particle size of at most 17 μm, preferably at most 16 or 14 μm, more preferably at most 12 μm. The invention further relates to a solid support, a process for preparing a procatalyst and said procatalyst as well as polyolefins obtained using said procatalyst.