Supported Catalyst Systems Reducing Aluminoxane Content
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Solution Overview
Problem
Existing catalyst systems for olefin polymerization with reduced aluminoxane content suffer from decreased productivity and polymer morphology issues, and require complex preparation processes involving prepolymerization and multiple washing steps.
Innovation Solution
A process for preparing catalyst solids using a finely divided support combined with aluminoxane, followed by the addition of the reaction product of a metallocene compound and an organometallic compound, which reduces the need for excess aluminoxane and simplifies the preparation process while maintaining high productivity and polymer quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If reduced amounts of aluminoxane are used in catalyst systems, then cost is reduced, but productivity and polymer morphology deteriorate
Solution Approach 1:
An organometallic compound is introduced as an intermediary substance that mediates between the metallocene catalyst and the reduced aluminoxane content. This intermediary enhances the catalytic activity and allows the system to maintain high productivity even with significantly reduced aluminoxane quantities, thereby resolving the contradiction between cost reduction and productivity maintenance
Solution Approach 2:
The invention changes the chemical parameters of the catalyst system by introducing an organometallic compound with specific properties (different from traditional aluminoxane). This parameter change enables the system to achieve high catalytic activity and maintain polymer morphology quality while using reduced aluminoxane content, thus resolving the contradiction between aluminoxane reduction and productivity maintenance
2Quantity of substance
If reduced amounts of aluminoxane are used, then cost is reduced, but polymer morphology deteriorates
Solution Approach 1:
The organometallic compound acts as a mediator that protects polymer morphology quality even when aluminoxane content is reduced. It interacts with the metallocene catalyst to maintain the catalytic sites' ability to produce well-formed polymer structures, thereby preventing morphology deterioration despite lower aluminoxane levels
Solution Approach 2:
By changing the chemical composition parameters of the catalyst system through the addition of organometallic compound, the invention maintains the conditions necessary for good polymer morphology formation. This parameter change compensates for the reduced aluminoxane content and prevents morphology degradation
3Quantity of substance
If traditional catalyst preparation methods are used with reduced aluminoxane, then aluminoxane consumption is reduced, but preparation complexity increases due to required prepolymerization and washing steps
Solution Approach 1:
The organometallic compound is incorporated into the catalyst preparation stage itself, performing a preliminary function that eliminates the need for subsequent prepolymerization steps. This preliminary action simplifies the overall preparation process while maintaining reduced aluminoxane consumption
Solution Approach 2:
The invention extracts and removes the unnecessary prepolymerization and multiple washing steps from the preparation process. By using the organometallic compound in the catalyst formulation, these complex steps become redundant, thereby simplifying the preparation process while maintaining aluminoxane reduction
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 achieves high productivity and good polymer morphology without forming deposits in polymerization reactors, and eliminates the need for prepolymerization and multiple washing steps, even with significantly reduced aluminoxane content.
Implementation Method 1
an aluminoxane firstly being produced by reaction of water with an organoaluminum compound
Implementation Method 2
adding the reaction product of a metallocene compound and an organometallic compound
Data Source
AI summary
The present invention relates to a process for preparing a catalyst solid for olefin polymerization, comprising a finely divided support, an aluminoxane and a metallocene compound, which comprises: a) firstly combining the finely divided support with the aluminoxane and subsequently b) adding the reaction product of a metallocene compound with at least one organometallic compound to the modified support, catalyst solids obtainable by this process, catalyst systems comprising these catalyst solids, their use for the polymerization of olefins and a process for the polymerization of olefins.