Two-Stage Olefin Oligomerization Catalyst Activation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high cost of aluminoxane activators in olefin oligomerization technologies and the inefficiency of using additional alkylaluminium compounds to enhance catalyst activity, leading to increased solids formation and reduced process economics.
Innovation Solution
A two-stage activation process using a combination of aluminoxane and trialkylaluminium as catalyst activators, where the oligomerization catalyst is first contacted with one activator component and then with the other, optimizing the molar ratios to reduce aluminoxane and total Al:Cr requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If aluminoxane activators are used to activate the oligomerisation catalyst, then catalyst activity is improved, but process cost increases due to the high cost of aluminoxane
Solution Approach 1:
The activation process is divided into two sequential stages: first contacting the catalyst with aluminoxane, then contacting with organylaluminium compound. This segmentation allows each activator to perform its optimal function at different stages, reducing the total aluminoxane requirement while maintaining high catalyst activity.
Solution Approach 2:
The organylaluminium compound acts as an intermediary that enhances the activation process. It is introduced in the second stage to modify the catalyst-activator complex formed in the first stage, thereby reducing the overall aluminoxane consumption while maintaining or improving catalyst activity.
2Productivity
If additional alkylaluminium compounds are added to enhance catalyst activity, then catalyst activity improves, but solids formation increases
Solution Approach 1:
The aluminoxane is introduced in the first stage to pre-activate the catalyst before the organylaluminium compound is added. This preliminary activation creates a catalyst-activator complex that is more receptive to the second activator, allowing for enhanced catalyst activity with reduced solids formation.
Solution Approach 2:
The sequential addition of activators changes the chemical parameters of the activation process. By controlling the order and timing of activator introduction, the molar ratios and chemical environment are optimized to reduce harmful solids formation while maintaining high catalyst activity.
3Productivity
If higher molar ratios of alkylaluminium are used, then catalyst activity increases, but total Al:Cr requirements increase leading to reduced process economics
Solution Approach 1:
The total aluminium content is segmented into two functional components added at different stages. This allows the first activator (aluminoxane) to provide essential activation while the second activator (organylaluminium) provides supplementary enhancement, optimizing the overall Al:Cr ratio for economic efficiency.
Solution Approach 2:
The sequential activation process enables optimization of the molar ratios of both activators relative to the catalyst. By controlling the parameters of each stage independently, the total aluminium requirement is minimized while achieving the desired catalyst activity level.
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 approach enhances catalyst activity while minimizing solids formation, achieving higher efficiency and reducing the amount of aluminoxane needed, thus lowering process costs and improving product selectivity.
Implementation Method 1
a catalyst for use in the oligomerisation of olefinic compounds wherein the catalyst has been activated in two stages by two catalyst activators
Data Source
AI summary
This invention relates to the oligomerisation of olefinic compounds in the presence of an oligomerisation catalyst activated in two stages by two catalyst activators According to the invention there is provided a process for activating an oligomerisation catalyst by contacting the catalyst with i) a first activator component selected from the group consisting of the aluminoxanes and a mixture of at least one aluminoxane and at least one organylaluminium compound, and ii) a second activator component which is an organylaluminium compound, the process being characterised therein that the oligomerisation catalyst is first contacted with one of the first activator component or second activator component, and the resulting mixture is thereafter contacted with the other of the first activator component or second activator component