Polyethylene from Ethanol/Manufacturing Instructions - Revision history

Poli: /* Ethylene polymerization */

2012-06-04T12:04:07Z

Ethylene polymerization

← Older revision		Revision as of 12:04, 4 June 2012
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	=Ethylene polymerization=		=Ethylene polymerization=
	An OS Ziegler-Natta catalyst as reported by Goeke is proposed as a first generation polymerization catalyst that is economical and robust. Ti/Mg based catalysts are the foundation of much of the polymerization industry, ~~and require~~ an electron donating solvent (tetrahydrofuran THF), and an activator of triethylaluminium (TAE). Impregnation of catalyst on a silica base increases the interaction of the substrate and catalyst increasing activity of the catalyst. Comonomers may also be included and terminal alkenes are useful for terminating polymer lengthening and controlling product density. Reactor beds may be primed with a polymer to help initiate polymerization and allow removal of product from the reaction bed soon after startup.		An OS Ziegler-Natta catalyst as reported by Goeke is proposed as a first generation polymerization catalyst that is economical and robust. Ti/Mg based catalysts are the foundation of much of the polymerization industry, requiring an electron donating solvent (tetrahydrofuran THF), and an activator of triethylaluminium (TAE). Impregnation of catalyst on a silica base increases the interaction of the substrate and catalyst, and increasing activity of the catalyst. Comonomers may also be included and terminal alkenes are useful for terminating polymer lengthening and controlling product density. Reactor beds may be primed with a polymer to help initiate polymerization and allow removal of product from the reaction bed soon after startup.

	==Catalyst preparation==		==Catalyst preparation==

Poli: /* Ethanol dehydration */

2012-06-04T12:02:02Z

Ethanol dehydration

← Older revision		Revision as of 12:02, 4 June 2012
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	=Ethanol dehydration=		=Ethanol dehydration=
	It has been known in the art that aluminium (III) oxide (AlO3) is capable of catalyzing the ~~reaction~~ with heat and the addition of transition metals can assist the reaction. Chen et al conducted a comprehensive study on transition metal doped aluminium catalysts. They found gamma aluminium oxide doped with Ti02 to have 99%+ yields and selectivity and be superior to other metals.		It has been known in the art that aluminium (III) oxide (AlO3) is capable of catalyzing the dehydration of ethanol to ethylene with heat, and the addition of transition metals can assist the reaction. Chen et al conducted a comprehensive study on transition metal doped aluminium catalysts. They found gamma aluminium oxide doped with Ti02 to have 99%+ yields and selectivity and be superior to other metals. An adapted protocol is below.

	==Catalyst preparation protocol==		==Catalyst preparation protocol==

Poli: /* catalyst preparation */

2012-06-03T15:49:54Z

catalyst preparation

← Older revision		Revision as of 15:49, 3 June 2012
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	An OS Ziegler-Natta catalyst as reported by Goeke is proposed as a first generation polymerization catalyst that is economical and robust. Ti/Mg based catalysts are the foundation of much of the polymerization industry, and require an electron donating solvent (tetrahydrofuran THF), and an activator of triethylaluminium (TAE). Impregnation of catalyst on a silica base increases the interaction of the substrate and catalyst increasing activity of the catalyst. Comonomers may also be included and terminal alkenes are useful for terminating polymer lengthening and controlling product density. Reactor beds may be primed with a polymer to help initiate polymerization and allow removal of product from the reaction bed soon after startup.		An OS Ziegler-Natta catalyst as reported by Goeke is proposed as a first generation polymerization catalyst that is economical and robust. Ti/Mg based catalysts are the foundation of much of the polymerization industry, and require an electron donating solvent (tetrahydrofuran THF), and an activator of triethylaluminium (TAE). Impregnation of catalyst on a silica base increases the interaction of the substrate and catalyst increasing activity of the catalyst. Comonomers may also be included and terminal alkenes are useful for terminating polymer lengthening and controlling product density. Reactor beds may be primed with a polymer to help initiate polymerization and allow removal of product from the reaction bed soon after startup.

	==~~catalyst~~ preparation==		==Catalyst preparation==
	1. In a 5 liter flask combine anhydrous 41.8g (0.438 mol) MgCl2, in 2.5 l tetrahydrofuran (THF). Add 27.7 g (0.184 mol) TiCl4 in dropwise over 30 min with stir bar agitation. Add heat ~60 C for 30 min to completely dissolve TiCl4.		1. In a 5 liter flask combine anhydrous 41.8g (0.438 mol) MgCl2, in 2.5 l tetrahydrofuran (THF). Add 27.7 g (0.184 mol) TiCl4 in dropwise over 30 min with stir bar agitation. Add heat ~60 C for 30 min to completely dissolve TiCl4.
	THF 66 C boiling point		THF 66 C boiling point

Poli at 15:25, 3 June 2012

2012-06-03T15:25:18Z

← Older revision		Revision as of 15:25, 3 June 2012
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	4. The calcined catalyst is crushed and sieved through 30-50 mesh.		4. The calcined catalyst is crushed and sieved through 30-50 mesh.

			==Reactor configuration==
			[[File:Detailed_Fluidized_bed_reactor_for_ethylene_production.png]]

	==Dehydration reaction protocol==		==Dehydration reaction protocol==
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	4. Prepare triethylaluminum in isopentane in 5-30% (v/v). Add to heated and loaded reactor.		4. Prepare triethylaluminum in isopentane in 5-30% (v/v). Add to heated and loaded reactor.

			==Reactor configuration==
			[[File:Detailed_Fluidized_bed_reactor_for_polyethylene_polymerization.png]]

	==Polymerization reaction protocol==		==Polymerization reaction protocol==

Poli: /* Ethylene polymerization */

2012-06-03T15:00:56Z

Ethylene polymerization

← Older revision		Revision as of 15:00, 3 June 2012
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	=Ethylene polymerization=		=Ethylene polymerization=
	An OS Ziegler-Natta catalyst as reported by Goeke is proposed as a first generation polymerization catalyst that is economical and robust. Ti/Mg based catalysts are the foundation of much of the polymerization industry, and require an electron donating solvent (tetrahydrofuran THF), and an activator of triethylaluminium (TAE). Impregnation of catalyst on a silica base increases the interaction of the substrate and catalyst increasing activity of the catalyst.		An OS Ziegler-Natta catalyst as reported by Goeke is proposed as a first generation polymerization catalyst that is economical and robust. Ti/Mg based catalysts are the foundation of much of the polymerization industry, and require an electron donating solvent (tetrahydrofuran THF), and an activator of triethylaluminium (TAE). Impregnation of catalyst on a silica base increases the interaction of the substrate and catalyst increasing activity of the catalyst. Comonomers may also be included and terminal alkenes are useful for terminating polymer lengthening and controlling product density. Reactor beds may be primed with a polymer to help initiate polymerization and allow removal of product from the reaction bed soon after startup.

	==catalyst preparation==		==catalyst preparation==

Poli: /* Polymerization reaction protocol */

2012-06-03T14:57:30Z

Polymerization reaction protocol

← Older revision		Revision as of 14:57, 3 June 2012
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	2. A temperature of 95-100 C is established and the reactor pressurized to 150-350 psi.		2. A temperature of 95-100 C is established and the reactor pressurized to 150-350 psi.

	3. Ethylene is added to the reactor in a mixture of nitrogen and hydrogen in a molar ratio of (5:3:2) with a gas flow of 2 m/s. TAE (5%) is added to the reactor in a molar ratio of 15-40 Al/Ti and 2-10% of the reaction mixture. A terminal alkene of C3-C8 is added to the mixture in the amount of 2-10% to control polymer density and acts to terminate chain lengthening. Controlling the density of the polymer is important to making products suitable for different applications. ~~Low density polymer is suitable to being drawn into a film~~ and a high density polymer is more suitable for injection molding.		3. Ethylene is added to the reactor in a mixture of nitrogen and hydrogen in a molar ratio of (5:3:2) with a gas flow of 2 m/s. TAE (5%) is added to the reactor in a molar ratio of 15-40 Al/Ti and 2-10% of the reaction mixture. A terminal alkene of C3-C8 is added to the mixture in the amount of 2-10% to control polymer density and acts to terminate chain lengthening.

			Controlling the density of the polymer is important to making products suitable for different applications. A low percentage (>2%) of comonomer will not terminate many polymers and result in a high density polymer more suitable for injection molding. A high percentage (2-10%) of comonomer will terminate many polymers and result in a low density polymer suitable to being drawn into a film.

	4. Polythylene product is removed at the rate of formation as determined by the loss of ethylene in the recycle stream.		4. Polythylene product is removed at the rate of formation as determined by the loss of ethylene in the recycle stream.

Poli at 14:50, 3 June 2012

2012-06-03T14:50:12Z

← Older revision		Revision as of 14:50, 3 June 2012
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	Instructions for construction of fluid bed reactor can be found on its own [[Fluidized bed reactor \| wikipage]].		Instructions for construction of fluid bed reactor can be found on its own [[Fluidized bed reactor \| wikipage]].

	=Ethanol dehydration ~~catalyst preparation protocol~~=		=Ethanol dehydration=
			It has been known in the art that aluminium (III) oxide (AlO3) is capable of catalyzing the reaction with heat and the addition of transition metals can assist the reaction. Chen et al conducted a comprehensive study on transition metal doped aluminium catalysts. They found gamma aluminium oxide doped with Ti02 to have 99%+ yields and selectivity and be superior to other metals.

	~~Gamma aluminium oxide doped with Ti02 has been reported to have 99%+ yields and selectivity and has been shown to be superior to other metals.~~		==Catalyst preparation protocol==

	Protocol for preparation:		Protocol for preparation:
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	4. The calcined catalyst is crushed and sieved through 30-50 mesh.		4. The calcined catalyst is crushed and sieved through 30-50 mesh.

	=Dehydration reaction protocol=		==Dehydration reaction protocol==
	1. The reaction zone is filled with catalyst, sealed, and connected to the subsystems.		1. The reaction zone is filled with catalyst, sealed, and connected to the subsystems.

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	4. Gas products flow through the three temperature phase liquid condenser and liquid water is removed and gaseous ethylene stored.		4. Gas products flow through the three temperature phase liquid condenser and liquid water is removed and gaseous ethylene stored.

	=Ethylene polymerization ~~catalyst preparation~~=		=Ethylene polymerization=
	~~A simple~~ Ziegler-Natta catalyst as reported by Goeke is proposed as a first generation polymerization catalyst that is economical and robust. Ti/Mg based catalysts are the foundation of much of the polymerization industry, and require an electron donating solvent (tetrahydrofuran THF), activator of triethylaluminium (TAE). Impregnation of catalyst on a silica base increases the interaction of the substrate and catalyst increasing activity of the catalyst		An OS Ziegler-Natta catalyst as reported by Goeke is proposed as a first generation polymerization catalyst that is economical and robust. Ti/Mg based catalysts are the foundation of much of the polymerization industry, and require an electron donating solvent (tetrahydrofuran THF), and an activator of triethylaluminium (TAE). Impregnation of catalyst on a silica base increases the interaction of the substrate and catalyst increasing activity of the catalyst.

			==catalyst preparation==
	1. In a 5 liter flask combine anhydrous 41.8g (0.438 mol) MgCl2, in 2.5 l tetrahydrofuran (THF). Add 27.7 g (0.184 mol) TiCl4 in dropwise over 30 min with stir bar agitation. Add heat ~60 C for 30 min to completely dissolve TiCl4.		1. In a 5 liter flask combine anhydrous 41.8g (0.438 mol) MgCl2, in 2.5 l tetrahydrofuran (THF). Add 27.7 g (0.184 mol) TiCl4 in dropwise over 30 min with stir bar agitation. Add heat ~60 C for 30 min to completely dissolve TiCl4.
	THF 66 C boiling point		THF 66 C boiling point
Line 42:		Line 44:
	4. Prepare triethylaluminum in isopentane in 5-30% (v/v). Add to heated and loaded reactor.		4. Prepare triethylaluminum in isopentane in 5-30% (v/v). Add to heated and loaded reactor.

	=Polymerization reaction protocol=		==Polymerization reaction protocol==
	1. The reactor is filled with the activated catalyst (~500 ml) on a silica support and an electron donating solvent such as tetrahydrofuran (THF).		1. The reactor is filled with the activated catalyst (~500 ml) on a silica support and an electron donating solvent such as tetrahydrofuran (THF).

	2. A temperature of 95-100 C is established and the reactor pressurized to 150-350 psi.		2. A temperature of 95-100 C is established and the reactor pressurized to 150-350 psi.

	3. Ethylene is added to the reactor in a mixture of nitrogen and hydrogen in a molar ratio of (5:3:2) with a gas flow of 2 m/s. TAE (5%) is added to the reactor in a molar ratio of 15-40 Al/Ti and 2-10% of the reaction mixture. A terminal alkene of C3-C8 is added to the mixture in the amount of 2-10% to control polymer density and acts to terminate chain lengthening. Controlling the density of the polymer is important to making products suitable for different applications~~, such as a low~~ density polymer is suitable to being drawn into a film and a high density polymer is more suitable for injection molding.		3. Ethylene is added to the reactor in a mixture of nitrogen and hydrogen in a molar ratio of (5:3:2) with a gas flow of 2 m/s. TAE (5%) is added to the reactor in a molar ratio of 15-40 Al/Ti and 2-10% of the reaction mixture. A terminal alkene of C3-C8 is added to the mixture in the amount of 2-10% to control polymer density and acts to terminate chain lengthening. Controlling the density of the polymer is important to making products suitable for different applications. Low density polymer is suitable to being drawn into a film and a high density polymer is more suitable for injection molding.

	4. Polythylene product is removed at the rate of formation as determined by the loss of ethylene in the recycle stream.		4. Polythylene product is removed at the rate of formation as determined by the loss of ethylene in the recycle stream.

Poli: /* Ethylene polymerization catalyst preparation */

2012-06-02T14:11:19Z

Ethylene polymerization catalyst preparation

← Older revision		Revision as of 14:11, 2 June 2012
Line 31:		Line 31:

	=Ethylene polymerization catalyst preparation=		=Ethylene polymerization catalyst preparation=
			A simple Ziegler-Natta catalyst as reported by Goeke is proposed as a first generation polymerization catalyst that is economical and robust. Ti/Mg based catalysts are the foundation of much of the polymerization industry, and require an electron donating solvent (tetrahydrofuran THF), activator of triethylaluminium (TAE). Impregnation of catalyst on a silica base increases the interaction of the substrate and catalyst increasing activity of the catalyst

	1. In a 5 liter flask combine anhydrous 41.8g (0.438 mol) MgCl2, in 2.5 l tetrahydrofuran (THF). Add 27.7 g (0.184 mol) TiCl4 in dropwise over 30 min with stir bar agitation. Add heat ~60 C for 30 min to completely dissolve TiCl4.		1. In a 5 liter flask combine anhydrous 41.8g (0.438 mol) MgCl2, in 2.5 l tetrahydrofuran (THF). Add 27.7 g (0.184 mol) TiCl4 in dropwise over 30 min with stir bar agitation. Add heat ~60 C for 30 min to completely dissolve TiCl4.
	THF 66 C boiling point		THF 66 C boiling point

	2. Dry 500 g silica at 800 C for 2 hr. Combine with 25 g ~~TAE~~ in 2 l THF at 60 C for 15 min. Dried activated silica at 65 C.		2. Dry 500 g silica at 800 C for 2 hr. Combine with 25 g triethylaluminum in 2 l THF at 60 C for 15 min. Dried activated silica at 65 C.

	3. Impregnate support by combining 500 g porous silica with catalyst precursor mixture at 60 C. Dry the mixture at 60 C under N2 for 3-5 hr. Find method to control drying and ED content.		3. Impregnate support by combining 500 g porous silica with catalyst precursor mixture at 60 C. Dry the mixture at 60 C under N2 for 3-5 hr. Find method to control drying and ED content.

Poli: /* Ethanol dehydration catalyst preparation protocol */

2012-06-02T14:04:52Z

Ethanol dehydration catalyst preparation protocol

← Older revision		Revision as of 14:04, 2 June 2012
Line 8:		Line 8:

	=Ethanol dehydration catalyst preparation protocol=		=Ethanol dehydration catalyst preparation protocol=

	~~Base treated gamma aluminium oxide has been report to have 90%+ yields and 97%+ selectivity and could be a 1st generation catalyst.~~

	Gamma aluminium oxide doped with Ti02 has been reported to have 99%+ yields and selectivity and has been shown to be superior to other metals.		Gamma aluminium oxide doped with Ti02 has been reported to have 99%+ yields and selectivity and has been shown to be superior to other metals.

	"30 g g-Al2O3 powder with BET speciﬁc surface areas of 200 m2/g are diluted and mixed well with a small quantity of 0.5 mol/L Na2CO3 solution in a three-necked rounded-bottomed ﬂask. Then, to the ﬂask, and agitate well with a magnetic stirrer. Keep the pH of the solution at 7–8, and then the material is washed to eliminate (SO4)2 via a centrifugal machine, followed by dried at 110 8C for 8 h and calcined at 500 C for 4 h. Finally, the TiO2/g-Al2O3 catalysts with the size of 30–50 mesh are obtained after forming, crushing and sieving" Chen et al.

	Protocol for preparation:		Protocol for preparation:
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	4. The calcined catalyst is crushed and sieved through 30-50 mesh.		4. The calcined catalyst is crushed and sieved through 30-50 mesh.

	~~Prepare reagents~~

	=Dehydration reaction protocol=		=Dehydration reaction protocol=

Poli: /* Polymerization reaction protocol */

2012-06-02T14:01:31Z

Polymerization reaction protocol

← Older revision		Revision as of 14:01, 2 June 2012
Line 53:		Line 53:
	3. Ethylene is added to the reactor in a mixture of nitrogen and hydrogen in a molar ratio of (5:3:2) with a gas flow of 2 m/s. TAE (5%) is added to the reactor in a molar ratio of 15-40 Al/Ti and 2-10% of the reaction mixture. A terminal alkene of C3-C8 is added to the mixture in the amount of 2-10% to control polymer density and acts to terminate chain lengthening. Controlling the density of the polymer is important to making products suitable for different applications, such as a low density polymer is suitable to being drawn into a film and a high density polymer is more suitable for injection molding.		3. Ethylene is added to the reactor in a mixture of nitrogen and hydrogen in a molar ratio of (5:3:2) with a gas flow of 2 m/s. TAE (5%) is added to the reactor in a molar ratio of 15-40 Al/Ti and 2-10% of the reaction mixture. A terminal alkene of C3-C8 is added to the mixture in the amount of 2-10% to control polymer density and acts to terminate chain lengthening. Controlling the density of the polymer is important to making products suitable for different applications, such as a low density polymer is suitable to being drawn into a film and a high density polymer is more suitable for injection molding.

	4. Polythylene product is removed at the rate of formation as determined by the loss of ethylene in the recycle stream.		4. Polythylene product is removed at the rate of formation as determined by the loss of ethylene in the recycle stream.

	~~Ethyle~~