Arco Chemical Technology, L.p.

Paul T Bowman

Harry R Hinney

Bi Le-Khac

Robert L Meeker

George Combs

A process for making substantially non-crystalline double metal cyanide (DMC) catalysts having improved activity and performance is disclosed. The process comprises using a metal salt having an alkalinity within the range of about 0.2 to about 2.0 wt. % as metal oxide based on the amount of metal salt to prepare the catalyst. Surprisingly, important polyol properties such as viscosity and unsaturation improve when the alkalinity of the metal salt used to make the DMC catalyst is properly controlled. The process allows catalyst producers to enjoy the benefits of substantially non-crystalline DMC catalysts even when relatively inexpensive, technical-grade metal salts are used to make the catalyst.

Process for making double metal cyanide catalysts

Highly active double metal cyanide (DMC) complex catalysts and methods for making them are disclosed. The catalysts contain less than about 0.2 moles of metal salt per mole of DMC compound in the catalyst, and unlike other highly active DMC catalysts, are substantially crystalline. Polyether polyols made from the catalysts have low unsaturation and are useful for making many types of polyurethane products.

Highly active double metal cyanide complex catalysts

Improved double metal cyanide (DMC) catalysts useful for making epoxide polymers are disclosed. One catalyst is a paste of a double metal cyanide (DMC) compound, an organic complexing agent, and water. The paste comprises at least about 90 wt. % of particles having a particle size within the range of about 0.1 to about 10 microns as measured by light scattering in polyether polyol dispersions of the catalyst particles. Preferred catalysts have a bimodal particle size distribution. The paste catalyst is more active and simpler to prepare than powder DMC catalysts. Polyols made from the paste catalyst have low unsaturations, low viscosities, and narrow molecular weight distributions, and are useful in making a variety of polyurethane products.

Double metal cyanide catalysts and methods for making them

Improved double metal cyanide catalysts are disclosed. The substantially amorphous catalysts of the invention are more active for polymerizing epoxides than conventional DMC catalysts, which have a substantial crystalline component. Polyol products made with the catalysts are unusually clear, have exceptionally low unsaturations, and contain no detectable amount of low molecular weight polyol impurities. Methods of making the improved DMC catalysts are also disclosed. In one method, the reactants are intimately combined to produce a catalyst of the invention. In another method, an organic complexing agent is initially present in the reactant solutions.

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Hurricane, WV, United States of America

Paul T Bowman