Supported Catalyst Drying via Inert Gas Vacuum
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Solution Overview
Problem
Existing methods for drying supported catalysts in gas-phase polymerization processes are either time-consuming or lead to catalyst deactivation, particularly when using vacuum drying at elevated temperatures or inert gas methods that are less effective.
Innovation Solution
A process involving the use of reduced pressure under a flow of inert gas at temperatures below 40°C to dry supported catalysts, maintaining catalyst activity and reducing drying time without the need for higher temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vacuum drying is performed at elevated temperatures to reduce drying time, then productivity is improved, but catalyst activity is reduced due to deactivation
Solution Approach 1:
The invention changes the drying parameters by performing vacuum drying at low temperatures (below 40°C) instead of elevated temperatures, thereby resolving the contradiction between drying speed and catalyst activity maintenance
Solution Approach 2:
An inert gas is introduced as an intermediary medium during vacuum drying to prevent catalyst deactivation while maintaining efficient solvent removal, allowing both short drying time and preserved catalyst activity
2Reliability
If vacuum drying is performed at low temperatures to preserve catalyst activity, then catalyst activity is maintained, but drying time becomes unacceptably long
Solution Approach 1:
The inert gas acts as a mediator that enhances the drying efficiency at low temperatures by facilitating solvent evaporation and removal without requiring high temperature input, thus maintaining both catalyst activity and acceptable drying time
Solution Approach 2:
The invention optimizes the combination of vacuum pressure and inert gas flow rate parameters to achieve efficient drying at low temperatures, resolving the time-activity trade-off
3Reliability
If inert gas is used to carry away solvent molecules to preserve catalyst activity, then catalyst activity is maintained, but drying effectiveness is significantly reduced compared to vacuum
Solution Approach 1:
The invention merges vacuum drying with inert gas flow into a combined process that achieves both the effectiveness of vacuum (rapid drying) and the protective benefits of inert gas (catalyst activity preservation), overcoming the limitations of using either method alone
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 drying time while preserving catalyst activity and flowability, preventing deactivation and ensuring effective use in gas-phase polymerization processes.
Implementation Method 1
treating the obtained mixture at a reduced pressure under a flow of inert gas at a temperature equal to or below 40°C to obtain a supported catalyst
Implementation Method 2
conducting the drying step under vacuum, at the same time feeding an inert gas flow
Data Source
AI summary
The present invention refers to a process for the preparation of supported catalysts for the polymerization of olefins comprising at least a late transition metal complex, wherein the process comprises two steps In the first step a catalytically active component comprising at least one late transition metal complex, optionally in the presence of one or more cocatalysts is mixed with a support, and in the second step the obtained mixture is treated at a reduced pressure under a flow of inert gas at a temperature equal to or below 40°C to obtain a supported catalyst The method is especially useful for the preparation of dual supported catalysts, useful in the gasphase polymerization of olefins.