Solid Titanium Catalyst Component for Olefin Polymerization
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Solution Overview
Problem
Current Ziegler-Natta catalyst systems for olefin polymerization involve complex and costly processes with variations in internal donor composition and numerous steps, leading to inefficiencies in polymerization activity and stereoregularity.
Innovation Solution
A simplified process for preparing a solid titanium catalyst component, involving the contact of a dialkyl magnesium compound with a magnesium solubilizing compound, followed by the addition of a titanium compound and internal electron donor, with activation using a titanium compound and inert solvent, to produce a catalyst with specific particle size distribution and composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional Ziegler-Natta catalyst preparation methods are used, then catalyst activity and stereoregularity can be achieved, but the process becomes complex with numerous steps and varies in internal donor composition
Solution Approach 1:
The patent combines multiple separate steps into a single integrated reaction system. The magnesium compound, internal donor, and titanium compound are reacted together in one pot, eliminating the need for separate preparation steps for each component and their subsequent combination. This merging of operations reduces process complexity while maintaining catalyst performance.
Solution Approach 2:
The single reaction system serves multiple functions simultaneously: it prepares the magnesium carrier, incorporates the internal donor, and introduces the titanium component all in one operation. This multi-functional approach replaces the conventional multi-step process of separate carrier preparation, donor addition, and titanation steps.
2Manufacturing precision
If conventional multi-step catalyst preparation is used, then catalyst composition can be controlled, but the process becomes costly and time-consuming
Solution Approach 1:
The patent performs preliminary incorporation of the internal donor during the same reaction step as the titanium compound addition, rather than adding the donor in a subsequent step. This preliminary action ensures precise composition control while reducing the total time required for catalyst preparation.
Solution Approach 2:
The reaction system maintains continuous useful action by incorporating all components (magnesium compound, internal donor, titanium compound) in a single continuous reaction sequence. This eliminates the idle time and intermediate handling required in multi-step processes, reducing overall production time and cost.
3Shape
If in situ generation of internal donor is used, then catalyst particles can be formed, but the composition of internal donor varies
Solution Approach 1:
The patent segments the internal donor into specific, identifiable components that can be independently controlled and measured. By using defined compounds rather than in situ generated donors, the composition can be precisely controlled and replicated, eliminating variability while maintaining particle 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
The process results in a catalyst system with improved polymerization activity, stereoregularity, and reduced steps, enhancing the efficiency and cost-effectiveness of olefin polymerization while maintaining desired chemical composition and morphology.
Implementation Method 1
contacting a dialkyl magnesium compound with a magnesium solubilizing compound to form a reaction mixture, wherein contacting the dialkyl magnesium compound with the magnesium solubilizing compound results in formation of first reaction mixture comprising magnesium alkoxide in the reaction mixture
Implementation Method 2
adding a titanium compound to convert the magnesium alkoxide in the reaction mixture to form second reaction mixture
Implementation Method 3
adding at least one internal electron donor to obtain a catalyst component
Implementation Method 4
activating the catalyst component using a solution comprising a titanium compound and an inert solvent
Implementation Method 5
activating the catalyst component using a solution comprising a titanium compound and an inert solvent and recovering a solid titanium catalyst component
Implementation Method 6
recovering a solid titanium catalyst component
Data Source
AI summary
The present invention provides a process for preparation of a solid titanium catalyst component for use as pro-catalyst for a Ziegler-Natta catalyst system. The solid titanium catalyst component comprises a combination of 15 to 20 wt % of a magnesium moiety, 1.0 to 6.0 wt % of a titanium moiety and 5.0 to 20 wt % of an internal donor, said solid titanium catalyst component has an average particle size in the range of 1 to 100 μm, characterized by a three point particle size distribution of D10 in the range of 1 to 10 μm; D50 in the range of to 25 μm and D90 in the range of 15 to 50 μm. The present invention also provides a 15 Ziegler-Natta catalyst system comprising the solid titanium catalyst component and the method of polymerizing and/or copolymerizing olefins by using the Ziegler-Natta catalyst system.