Polyisobutylene Production Process With Improved Efficiencies And/Or For Forming Products Having Improved Characteristics And Polyisobutylene Products Produced Thereby

Abstract

A process for production of polyisobutylene includes subjecting a reaction admixture comprising isobutylene, a diluent for the isobutylene, which may be isobutane, and a catalyst composition, that may include a BF 3 /methanol catalyst complex, to reaction conditions suitable for causing at least a portion of the isobutylene to undergo polymerization to form a polyisobutylene product including polyisobutylene molecules. At least a fraction of the polyisobutylene molecules thus produced have alpha position double bonds and the polyisobutylene product has a number average molecular weight (M N ) and a polydispersity index (PDI). The concentration of the diluent in the reaction admixture may be manipulated to control or change any one or more of (a) the relative size of the fraction, (b) the number average molecular weight of the product, (c) the polydispersity index of the product and (d) the relative size of the portion. The diluent concentration may be held constant to maintain any one or more of such characteristics constant.

1 . A process for production of polyisobutylene comprising:
 subjecting a reaction admixture comprising isobutylene, a diluent for said isobutylene and a catalyst composition to reaction conditions suitable for causing at least a portion of said isobutylene to undergo polymerization to form a polyisobutylene product including polyisobutylene molecules, at least a fraction of said polyisobutylene molecules having alpha position double bonds, said polyisobutylene product having a number average molecular weight and a polydispersity index; and   manipulating the concentration of said diluent in said admixture to thereby control any one or more of (a) the relative size of said fraction, (b) the number average molecular weight of said product, (c) the polydispersity index of said product and (d) the relative size of said portion.   
     
     
         2 . A process as set forth in  claim 1 , wherein said diluent comprises isobutane. 
     
     
         3 . A process as set forth in  claim 1 , wherein said catalyst composition comprises BF 3 . 
     
     
         4 . A process as set forth in  claim 1 , wherein said catalyst composition comprises a complex of BF 3  and a complexing agent. 
     
     
         5 . A process as set forth in  claim 4 , wherein said complexing agent comprises a primary alcohol. 
     
     
         6 . A process as set forth in  claim 5 , wherein said complexing agent comprises methanol. 
     
     
         7 . A process as set forth in  claim 1 , wherein the relative size of said fraction is a direct function of the diluent concentration. 
     
     
         8 . A process as set forth in  claim 1 , wherein the polydispersity index is an indirect function of the diluent concentration. 
     
     
         9 . A process as set forth in  claim 1 , wherein the relative size of said portion is a direct function of the diluent concentration. 
     
     
         10 . A process as set forth in  claim 1 , wherein said reaction admixture is subjected to said reaction conditions in a reaction zone where the reaction admixture is maintained in an intimately intermixed condition. 
     
     
         11 . A process as set forth in  claim 10 , wherein said zone comprises a loop reactor reaction zone. 
     
     
         12 . A process as set forth in  claim 1 , comprising increasing the concentration of said diluent in said admixture to thereby increase the relative size of said fraction. 
     
     
         13 . A process as set forth in  claim 1 , comprising decreasing the concentration of said diluent in said admixture to thereby increase the polydispersity index of said product. 
     
     
         14 . A process as set forth in  claim 1 , comprising increasing the concentration of said diluent in said admixture to thereby increase the relative size of said portion. 
     
     
         15 . A process as set forth in  claim 1 , wherein the concentration of said diluent in said admixture is no more than about 50%. 
     
     
         16 . A process as set forth in  claim 1 , wherein the concentration of said diluent in said admixture is no more than about 30%. 
     
     
         17 . A process as set forth in  claim 6 , wherein said reaction admixture is subjected to said reaction conditions in a reaction zone where the reaction admixture is maintained in an intimately intermixed condition. 
     
     
         18 . A process as set forth in  claim 17 , wherein said zone comprises a loop reactor reaction zone. 
     
     
         19 . A process as set forth in  claim 17 , wherein the concentration of said isobutane in said admixture is no more than about 30%. 
     
     
         20 . A process as set forth in  claim 1 , further comprising selecting a diluent concentration for said admixture corresponding to a given relative size of said fraction, said manipulating step comprising maintaining the diluent content of the admixture at said selected concentration to thereby hold the relative size of said fraction essentially constant. 
     
     
         21 . A process as set forth in  claim 1 , further comprising selecting a diluent concentration for said admixture corresponding to a given polydispersity index level, said manipulating step comprising maintaining the diluent content of the admixture at said selected concentration to thereby hold the polydispersity index of said product essentially constant. 
     
     
         22 . A process as set forth in  claim 1 , further comprising selecting a diluent concentration for said admixture corresponding to a given relative size of said portion, said manipulating step comprising maintaining the diluent content of the admixture at said selected concentration to thereby hold the relative size of said portion essentially constant. 
     
     
         23 . A process for production of polyisobutylene comprising:
 subjecting a reaction admixture comprising isobutylene, a diluent for said isobutylene and a catalyst composition to reaction conditions suitable for causing at least a portion of said isobutylene to undergo polymerization to form a polyisobutylene product including polyisobutylene molecules, at least a fraction of said polyisobutylene molecules having alpha position double bonds, said polyisobutylene product having a number average molecular weight and a polydispersity index, said polyisobutylene product having at least one parameter that is variable as a function of the concentration of said diluent in said admixture, said at least one parameter comprising (a) the relative size of said fraction, (b) the number average molecular weight of said product, (c) the polydispersity index of said product or (d) the relative size of said portion;   choosing a diluent concentration corresponding to a pre-selected value of said at least one parameter; and   maintaining the admixture at said chosen diluent concentration to thereby hold said parameter at said pre-selected value.   
     
     
         24 . A process as set forth in  claim 23  wherein said at least one parameter comprises the relative size of said portion. 
     
     
         25 . A process as set forth in  claim 23  wherein said at least one parameter comprises the number average molecular weight of said product. 
     
     
         25 . A process as set forth in  claim 23  wherein said at least one parameter comprises the polydispersity index of said product. 
     
     
         26 . A process as set forth in  claim 23  wherein said at least one parameter comprises the relative size of said fraction. 
     
     
         27 . A process as set forth in  claim 23 , wherein said diluent comprises isobutane. 
     
     
         28 . A process as set forth in  claim 23 , wherein said catalyst composition comprises BF 3 . 
     
     
         29 . A process as set forth in  claim 23 , wherein said catalyst composition comprises a complex of BF 3  and a complexing agent. 
     
     
         30 . A process as set forth in  claim 29 , wherein said complexing agent comprises a primary alcohol. 
     
     
         31 . A process as set forth in  claim 30 , wherein said complexing agent comprises methanol. 
     
     
         32 . In a process for production of polyisobutylene wherein a reaction admixture including isobutylene, a diluent for said isobutylene and a catalyst composition is subjected to reaction conditions suitable for causing at least a portion of said isobutylene to undergo polymerization to form a polyisobutylene product including polyisobutylene molecules, wherein at least a fraction of said polyisobutylene molecules have alpha position double bonds and wherein said polyisobutylene product has a number average molecular weight and a polydispersity index, the improvement comprising increasing the concentration of the diluent in the admixture to thereby increase the relative size of said fraction, increase the relative size of said portion, decrease the number average molecular weight of said product, or decrease the polydispersity index of said product. 
     
     
         33 . In a process for production of polyisobutylene wherein a reaction admixture including isobutylene, a diluent for said isobutylene and a catalyst composition is subjected to reaction conditions suitable for causing at least a portion of said isobutylene to undergo polymerization to form a polyisobutylene product including polyisobutylene molecules, wherein at least a fraction of said polyisobutylene molecules have alpha position double bonds and wherein said polyisobutylene product has a number average molecular weight and a polydispersity index, the improvement comprising decreasing the concentration of the diluent in the admixture to thereby decrease the relative size of said fraction, decrease the relative size of said portion, increase the number average molecular weight of said product, or increase the polydispersity index of said product. 
     
     
         34 . A process for production of polyisobutylene comprising:
 subjecting a reaction admixture comprising isobutylene, a diluent for said isobutylene and a catalyst composition to reaction conditions in a reaction zone suitable for causing at least a portion of said isobutylene to undergo polymerization to form a polyisobutylene product including polyisobutylene molecules, at least a fraction of said polyisobutylene molecules having alpha position double bonds, said polyisobutylene product having a number average molecular weight and a polydispersity index, said polyisobutylene product having at least one parameter that is variable as a function of the concentration of said diluent in said admixture, said at least one parameter comprising (a) the relative size of said fraction, (b) the number average molecular weight of said product, (c) the polydispersity index of said product or (d) the relative size of said portion;   choosing a diluent concentration corresponding to a pre-selected value of said at least one parameter;   maintaining the admixture at said chosen diluent concentration to thereby hold said parameter at said pre-selected value;   treating said product to remove diluent and unreacted isobutylene therefrom; and   recycling at least one of the diluent and the unreacted isobutylene back to said zone.   
     
     
         35 . A polyisobutylene product produced by the process of  claim 1 . 
     
     
         36 . A polyisobutylene product produced by the process of  claim 6 . 
     
     
         37 . A polyisobutylene product produced by the process of  claim 12 . 
     
     
         38 . A polyisobutylene product produced by the process of  claim 13 . 
     
     
         39 . A polyisobutylene product produced by the process of  claim 20 . 
     
     
         40 . A polyisobutylene product produced by the process of  claim 21 . 
     
     
         41 . A polyisobutylene product produced by the process of  claim 23 . 
     
     
         42 . A polyisobutylene product produced by the process of  claim 25 . 
     
     
         43 . A polyisobutylene product produced by the process of  claim 26 . 
     
     
         44 . A polyisobutylene product produced by the process of  claim 31 . 
     
     
         45 . A polyisobutylene product produced by the process of  claim 32 . 
     
     
         46 . A polyisobutylene product produced by the process of  claim 33 . 
     
     
         47 . A polyisobutylene product produced by the process of  claim 34 . 
     
     
         48 . A process as set forth in  claim 1 ,  6 ,  12 ,  13 ,  20 ,  21 ,  23 ,  25 ,  26 ,  31 ,  32 ,  33  or  34 , wherein said diluent comprises a C 3 -C 16  alkane or alkene, or a mixture of such substances. 
     
     
         49 . A process as set forth in  claim 48 , wherein said diluent comprises a C 3 -C 16  1-alkene. 
     
     
         50 . A process as set forth in  claim 48 , wherein said diluent comprises isobutane. 
     
     
         51 . A polyisobutylene product as set forth in  claim 35 ,  36 ,  37 ,  38 ,  39 ,  40 ,  41 ,  42 ,  43 ,  44 ,  45 ,  46  or  47 , wherein the diluent comprises a C 3 -C 16  1-alkene. 
     
     
         52 . A polyisobutylene product as set forth in  claim 51 , wherein the diluent comprises a C 3 -C 16  1-alkene. 
     
     
         53 . A polyisobutylene product as set forth in  claim 51 , wherein the diluent comprises isobutane.