Spherical Dialkoxy Magnesium Support Preparation
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Solution Overview
Problem
Conventional methods for preparing dialkoxy magnesium supports for olefin polymerization catalysts often result in non-uniform particle size and shape, leading to issues like excessive macroparticles and reduced bulk density, which affect catalyst performance and polymer quality, especially in large-scale commercial processes.
Innovation Solution
A method involving the reaction of magnesium metal with a nitrogen halide to form MgX, followed by a reaction with alcohol in the presence of MgX, which stabilizes the process and reduces macroparticles, producing smooth-surfaced spherical particles with uniform size distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If magnesium metal reacts with alcohol using conventional methods, then the reaction proceeds rapidly, but excessive reaction heat and hydrogen are generated making it difficult to regulate reaction rate, resulting in microparticles and heterogeneous macroparticles
Solution Approach 1:
The patent introduces an intermediary substance (nitrogen halide or its derivative) that mediates between magnesium metal and alcohol. This intermediary first reacts with magnesium to form a surface layer, which then controls the reaction with alcohol, thereby regulating reaction rate and preventing uncontrolled rapid reactions that produce heterogeneous particles.
Solution Approach 2:
The patent applies preliminary action by first reacting nitrogen halide with magnesium metal before introducing alcohol. This preliminary reaction creates a surface layer on magnesium that controls subsequent alcohol reaction, preventing uncontrolled rapid reactions and ensuring uniform particle formation.
2Ease of manufacture
If conventional methods are used to prepare dialkoxy magnesium, then the process is simple, but the resulting particles have non-uniform size and shape with excessive macroparticles reducing bulk density
Solution Approach 1:
The patent uses nitrogen halide as an intermediary that modifies the reaction mechanism. It first forms a surface layer on magnesium, which then controls alcohol reaction, resulting in uniform spherical particles with narrow size distribution while maintaining process simplicity.
Solution Approach 2:
The patent changes the reaction parameters by introducing nitrogen halide as a mediator that controls reaction rate and heat generation. This parameter change enables controlled formation of uniform spherical particles with reduced macroparticles and improved bulk density.
3Productivity
If the reaction is highly exothermic and rapid, then productivity is high, but macroparticles are formed that deteriorate polymer flowability and cause problems in mass-production
Solution Approach 1:
The patent introduces nitrogen halide as an intermediary that moderates the highly exothermic reaction between magnesium and alcohol. This intermediary controls heat generation and reaction propagation, maintaining high productivity while preventing macroparticle formation that would harm polymer flowability.
Solution Approach 2:
The patent converts the potentially harmful rapid exothermic reaction into a beneficial controlled process. By using nitrogen halide as a mediator, the reaction heat and speed are channeled to produce uniform spherical particles with narrow size distribution, transforming the harmful rapid reaction into a beneficial controlled process.
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
This method significantly reduces the amount of macroparticles and achieves a uniform spherical shape, enhancing the suitability of the support for commercial olefin polymerization processes by improving catalyst activity and polymer stereoregularity.
Implementation Method 1
firstly, MgX(I) (X=halogen atm) is prepared by reacting a reaction initiator, nitrogen halide, with magnesium metal at same ratio in equivalent weight and then a reaction of magnesium metal and alcohol is performed in the presence of the MgX
Data Source
AI summary
Provided is a method of preparation of a spherical support for an olefin polymerization catalyst. Specifically, provided is a method of preparation of a support which can be used in preparation of an olefin polymerization catalyst, wherein, MgX(I) (X=halogen atom) is prepared by reacting a reaction initiator, nitrogen halide, and magnesium metal, and then magnesium metal and alcohol are reacted in the presence of the MgX, thereby resulting a smooth-surfaced spherical dialkoxy magnesium support having a uniform particle size distribution.