Spherical Alumina-MgCl2 Catalyst for Controlled Polyolefin Polymerization

Solution Overview

Problem

Catalysts based on mixed supports, such as Al2O3 and MgCl2, face challenges in maintaining controlled morphology and high activity, leading to uncontrolled polymerization reactions and agglomerate formation, especially under high partial pressures, making them difficult to implement in continuous processes without anti-agglutinant agents or requiring smaller monomer charges, which limits industrial feasibility.

Innovation Solution

A process involving a spherical support based on special alumina with controlled precipitation of magnesium chloride, forming a porous matrix that is then treated with alkyl aluminum and titanated, resulting in a catalyst with controlled morphology and enhanced catalytic activity suitable for various industrial systems, including batch and gas-phase processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If catalysts based on mixed supports (Al2O3 and MgCl2) are used to achieve high catalytic activity, then productivity is improved, but uncontrolled polymerization reactions and agglomerate formation occur

Engineering Contradiction:

Improvecatalytic activityVSAvoidprocess control

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-forming a spherical support with controlled morphology and pore structure before introducing the catalytic components. The support is prepared with specific physical characteristics (spherical shape, controlled porosity, defined surface area) that predetermine the polymerization behavior, preventing agglomerate formation while maintaining high activity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements local quality by creating a support structure with specific localized properties - spherical morphology with controlled pore distribution and surface characteristics. This localized structural control ensures uniform polymerization throughout the catalyst particles, preventing the uncontrolled reactions and agglomeration that occur with conventional mixed supports.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If grinding is used to prepare mixed catalyst to simplify manufacturing, then ease of manufacture is improved, but irregular morphology is produced leading to agglomerate formation

Engineering Contradiction:

Improvecatalyst preparationVSAvoidmorphology control

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent applies preliminary action by pre-forming a spherical support with controlled morphology and pore structure before introducing the catalytic components. The support is prepared with specific physical characteristics (spherical shape, controlled porosity, defined surface area) that predetermine the polymerization behavior, preventing agglomerate formation while maintaining high activity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements composite materials by combining Al2O3 and MgCl2 within a structured spherical support matrix. This composite structure maintains the benefits of mixed supports for catalytic activity while the unified spherical morphology prevents the irregular shapes and agglomeration problems associated with mechanically ground mixtures.

Inventive Principle:

Principle #40Composite materials

3Reliability

If smaller charges of monomer are used to avoid agglomerates, then process stability is improved, but productivity decreases

Engineering Contradiction:

Improveprocess stabilityVSAvoidproduction rate

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-forming a spherical support with controlled morphology and pore structure before introducing the catalytic components. The support is prepared with specific physical characteristics (spherical shape, controlled porosity, defined surface area) that predetermine the polymerization behavior, preventing agglomerate formation while maintaining high activity.

Inventive Principle:

Principle #10Preliminary action

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 exhibits improved controllability and productivity, maintaining high catalytic activity while preventing agglomerate formation, allowing for versatile use across different technological platforms and achieving superior mechanical properties in polyolefin production.

Implementation Method 1

controlled precipitation of magnesium chloride, forming a porous matrix

Methodology Applied

Scientific EffectPrecipitation: Precipitation

Implementation Method 2

treated with alkyl aluminum

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 3

catalyst of high activity based on a mixture of supports... for production of polyolefins

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS9193808B2Catalyst and process for obtaining catalyst of high activity

Publication Date: 2015.11.24 PETROLEO BRASILEIRO SA PETROBRAS

AI summary

The present invention relates to a process for obtaining a catalyst of high activity based on a mixture of supports, more specifically, the mixture of supports being Al2O3 plus MgCl2, intended for the production of polyolefins. The catalyst of the present invention involves the use of a spherical support based on special alumina that serves as a porous matrix, which is impregnated, by precipitation, with magnesium chloride by dissolving the latter in ethers and/or alcohols.