Ziegler-Natta Catalyst Preparation via Thermal After-Treatment
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Solution Overview
Problem
Existing processes for preparing Ziegler-Natta catalysts are time-consuming and energy-intensive, resulting in competitive disadvantages and polymers with broad molecular weight distribution, which limits their processing behavior and final properties.
Innovation Solution
A process involving the reaction of magnesium alkoxide with a tetravalent titanium compound, followed by thermal after-treatment without intermediate steps, to form a catalyst suitable for single-stage polymerization of olefins, achieving a medium to broad molar mass distribution and improved polymerization activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-step processes with washing and extended thermal after-treatment are used, then catalyst stability is improved, but preparation time and energy consumption increase significantly
Solution Approach 1:
The patent applies preliminary action by performing the thermal after-treatment step immediately after the reaction step, without intermediate washing or separation operations. The reaction product is directly subjected to thermal treatment at 100-200°C for 1-24 hours, which pre-preparates the catalyst in its active form, eliminating the need for subsequent washing steps and reducing overall preparation time while maintaining catalyst stability.
Solution Approach 2:
The patent merges the reaction step and thermal after-treatment step into a continuous process without intermediate washing operations. By combining these steps, the patent eliminates the time-consuming washing procedure while ensuring the catalyst achieves the necessary stability through direct thermal treatment of the reaction product.
2Power
If traditional catalyst preparation methods are used, then catalyst activity is maintained at acceptable levels, but polymer molecular weight distribution becomes broad, limiting processing behavior
Solution Approach 1:
The patent applies parameter changes by optimizing the thermal after-treatment conditions (temperature of 100-200°C and time of 1-24 hours) to control the catalyst's molecular weight distribution. By adjusting these parameters, the patent achieves a balance between maintaining high catalyst activity and producing polymers with uniform molecular weight distribution, which improves processing behavior and final product properties.
3Reliability
If extended thermal after-treatment for 18 hours is used, then catalyst stability is improved, but energy consumption increases significantly
Solution Approach 1:
The patent optimizes the thermal after-treatment parameters to achieve catalyst stability within a reasonable time frame. By adjusting temperature (100-200°C) and time (1-24 hours), the patent finds the optimal balance point where sufficient stability is achieved without requiring excessively long treatment times, thereby reducing energy consumption while maintaining catalyst performance.
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 reduces time and energy requirements, enhances polymerization activity, and produces polymers with uniform particle size distribution and regulated molar mass, suitable for films with excellent mechanical properties.
Implementation Method 1
the reaction product of a magnesium alkoxide with a tetravalent titanium compound
Implementation Method 2
the reaction product is then after-treated thermally at a temperature in the range from 90 to 200° C. for a period of from 10 to 180 minutes
Implementation Method 3
catalyst systems of the Ziegler-Natta type which comprise a component A which is obtained by reaction of magnesium alkoxide with a titanium compound
Data Source
AI summary
For the (co) polymerization of ethylene with other 1-olefins, a Ziegler catalyst which comprises the product from the reaction of a magnesium alkoxide suspended or dispersed as ge in an inert solvent with a tetravalent transition metal compound and is subjected to a thermal after-treatment for a period of not more than 180 minutes is prepared. The catalyst gives a high yield of a polymer powder which has a broad molar mass distribution and is best suited to the production of films, hollow bodies and pipes.