Non-precipitating alkali/alkaline earth metal and aluminum solutions made with diols having at least two primary hydroxyl groups
View Patent ↗A stable catalyst solution suitable for catalyzing the polycondensation of reactants to make polyester polymers comprising: (i) M, wherein M is represented by an alkaline earth metal or alkali metal and (ii) aluminum metal and (iii) a polyhydroxyl solvent having at least 3 carbon atoms and at least two primary hydroxyl groups, the longest carbon chain being a hydrocarbon; such as 1,3-propane diol, 1,4-butane diol, 1,5-pentane diol, or combinations thereof, wherein the molar ratio of M:Al ranges from 0.75:1 to less than 1.5:1. The catalyst solution is desirably a solution which does not precipitate upon standing over a period of at least one week at room temperature (25° C.-40° C.), even at molar ratios of M:Al approaching 1:1. There is also provided a method for the manufacture of the solution, its feed to and use in the manufacture of a polyester polymer, and polyester polymers obtained by combining certain ingredients or containing the residues of these ingredients in the composition.
1. A solution comprising:
(i) lithium,
(ii) aluminum isopropoxide, and
(iii) a polyhydroxyl solvent having at least 3 carbon atoms and at least two primary hydroxyl groups, the longest carbon chain being a hydrocarbon, selected from the group consisting of 1,3-propane diol, 1,4-butane diol, 1,5-pentane diol, and combinations thereof;
wherein the aluminum isopropoxide is present in an amount of from 2.2 to 8.4 wt % based on the total weight of the solution;
wherein the molar ratio of Li:Al ranges from 0.75:1 to less than 1.5:1, and
wherein no precipitation is visible to the naked eye when the solution is allowed to stand still over a period of at least one week at 25° C.
2. The solution of claim 1 , wherein the solution is sufficiently stable such that, if measured, no precipitation is visible to the naked eye when the solution is allowed to stand still over a period of at least three (3) weeks at 25° C.
3. The solution of claim 1 , wherein the solution contains at least 3000 ppm aluminum metal based on the weight of the solution.
4. The solution of claim 3 , wherein the solution contains at least 5000 ppm aluminum metal based on the weight of the solution.
5. The solution of claim 4 , wherein the solution contains at least 1 wt. % aluminum metal based on the weight of the solution.
6. The solution of claim 1 , wherein the molar ratio Li:Al is at least 0.85:1.
7. The solution of claim 1 , wherein the molar ratio Li:Al ranges from 0.75:1 to 1.3:1.
8. The solution of claim 1 , wherein the molar ratio Li:Al ranges from 0.75:1 to 1.25:1.
9. The solution of claim 1 , wherein the molar ratio Li:Al ranges from 0.8:1 to 1.25:1.
10. The solution of claim 1 , wherein the molar ratio Li:Al ranges from 0.85:1 to 1.2:1.
11. The solution of claim 1 , wherein the molar ratio Li:Al ranges from 0.9:1 to 1.15:1.
12. The solution of claim 1 , wherein the molar ratio Li:Al ranges from 0.75:1 to 1.1:1.
13. The solution of claim 1 , wherein the concentration of the aluminum metal is at least 3000 ppm, and the molar ratio of Li:Al ranges from 0.8:1 to 1.2:1.
14. The solution of claim 1 , wherein the primary hydroxyl groups are the only end group reactive functionalities on the solvent compound.
15. The solution of claim 1 , wherein the solution comprises said solvent in an amount of at least 60 wt. % based on the weight of liquids in the solution.
16. The solution of claim 1 , wherein the solution comprises said solvent in an amount of at least 80 wt. % based on the weight of liquids in the solution.
17. The solution of claim 1 , wherein the amount of aluminum metal in the solution is at least 3000 ppm, and the molar ratio of Li:Al ranges from 0.75:1 to 1.3:1.
18. The solution of claim 1 , wherein said period is at least three (3) weeks and the molar ratio of Li:Al ranges from 0.8:1 to 1.2:1.
19. A polyester polymer composition comprising a catalyst system and a polyester polymer, at least part of said catalyst system obtained by a solution comprising
(i) lithium,
(ii) aluminum isopropoxide, and
(iii) a polyhydroxyl solvent having at least 3 carbon atoms and at least two primary hydroxyl groups, the longest carbon chain being a hydrocarbon, selected from the group consisting of 1,3-propane diol, 1,4-butane diol, 1,5-pentane diol, and combinations thereof;
wherein the molar ratio of Li:Al ranges from 0.75:1 to less than 1.5:1,
wherein the aluminum isopropoxide is present in an amount of from 2.2 to 8.4 wt % based on the total weight of the solution; and
wherein no precipitation is visible to the naked eye when the solution is allowed to stand still over a period of at least one (1) week at 25° C.
20. The polyester polymer composition of claim 19 , wherein the polyester polymer comprises a polyethylene terephthalate polymer.
21. The polyester polymer composition of claim 20 , wherein the concentration of aluminum metal in the solution is at least 3000 ppm.
22. The polyester polymer composition of claim 20 , wherein the composition further comprises residues of phosphorus.
23. The polyester polymer composition of claim 20 , wherein the molar ratio Li:Al ranges from 0.75:1 to 1.2:1.
24. The polyester polymer composition of claim 20 , wherein the polyester polymer has an It.V. of at least 0.70 dL/g obtained from a melt phase polymerization process.
25. The polyester polymer composition of claim 19 , wherein said polyester polymer has an It.V. of at least 0.70 dL/g obtained from a melt phase polymerization process and the molar ratio of Li:Al ranges from 0.75:1 to 1.2:1.
26. A bottle preform obtained from the polyester polymer composition of claim 19 .
27. A beverage bottle obtained from the polyester polymer composition of claim 19 .