Spray-Dried Catalyst Systems for Polymerization Productivity
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Solution Overview
Problem
Current catalyst systems face productivity issues due to the decrease in catalyst activity when supported on inert carriers, and large particles from these carriers can adversely affect polymer properties, particularly in film applications where they appear as defects or gels.
Innovation Solution
A method for producing a catalyst system by spray drying a composition comprising a solvent, a single-site catalyst component, and an inert gas heated to a lower temperature range of 100°C to 150°C, which increases the productivity of the catalyst system and reduces reactor temperatures for more efficient polymerization processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If catalyst is supported on inert carrier, then catalyst can be delivered to reactor, but catalyst activity decreases significantly
Solution Approach 1:
The invention extracts and removes the inert carrier support from the catalyst system, delivering only the active catalyst component to the reactor. This eliminates the harmful effect of carrier support on catalyst activity while maintaining the ability to deliver catalyst to the reactor through alternative means.
Solution Approach 2:
The invention uses a slurry medium as an intermediary to deliver the catalyst to the reactor. Instead of using inert carrier particles, the catalyst is suspended in a liquid slurry that serves as the delivery vehicle, allowing catalyst transport without the harmful effects of solid carrier support.
2Ease of manufacture
If large particles of support material are used, then catalyst can be handled, but polymer properties are adversely affected with defects or gels
Solution Approach 1:
The invention extracts and eliminates the solid support material entirely from the system. By removing the carrier particles that cause defects in the polymer product, the invention achieves high polymer quality without compromising catalyst handling capability through the use of slurry delivery.
3Manufacturing precision
If traditional spray drying temperature is used, then catalyst composition is dried, but catalyst productivity is reduced
Solution Approach 1:
The invention changes the drying temperature parameter from traditional high temperatures to a lower temperature range. This parameter modification prevents the formation of large inert particles during spray drying while still achieving effective drying of the catalyst composition, thereby maintaining high catalyst productivity.
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 modified spray-drying process enhances catalyst productivity by up to 40% compared to traditional methods, reducing the presence of large inert particles in the polymer product and improving polymerization efficiency.
Implementation Method 1
heating an inert gas to a temperature in a range of from 100°C to 150°C
Implementation Method 2
spray drying the catalyst composition in the presence of the inert gas to form a spray-dried catalyst system
Data Source
AI summary
Methods for producing catalyst systems with increased productivity are disclosed. The methods may comprise providing a catalyst composition comprising a solvent and a single-site catalyst component, heating an inert gas to a temperature in a range of from about 100°C to about 150°C, and spray drying the catalyst composition in the presence of the inert gas to form a spray-dried catalyst system. Additionally, the methods may comprise providing a catalyst composition comprising a solvent, an activator, a filler material, a metallocene catalyst, and a Group 15 -containing catalyst; heating an inert gas to a temperature in a range of from about 100°C to about 150°C; and spray drying the catalyst composition in the presence of the inert gas to form a spray-dried catalyst system.