Methods and systems for controlling polymer particle size
AssigneeChevron Phillips Chemical Company LP
InventorsJohn D. Hottovy, Gregory G. Hendrickson
Life of this patent
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Abstract
Techniques are provided for producing polymer particles of a size just slightly larger than the size of polymer fines. The technique may prevent or limit the occurrence of reactor fouls associated with large polymer particles. The technique also may provide a greater weight percentage of solids in the reactor. The desired polymer particle size may be achieved by employing a catalyst having particles of a size determined based on the expected catalyst productivity. In certain embodiments, the catalyst particle size may be determined based on the expected catalyst productivity, the polymer particle density, the catalyst particle density, and/or the polymer particle size.
Claims20
A system for producing polymer particles, the system comprising:
- a polymerization reactor configured to polymerize monomer on a catalyst to form a plurality of polymer particles;
- a controller configured to determine an expected catalyst productivity based on expected polymerization conditions within the polymerization reactor;
- one or more feed locations configured to direct the monomer and the catalyst into the polymerization reactor, wherein the catalyst comprises catalyst particles with an average catalyst particle size selected based on the expected catalyst productivity;
- and
- a reactor outlet configured to remove the polymer particles from the polymerization reactor, wherein 70 to 90 percent by weight of the polymer particles have an individual polymer particle size of 100 to 500 microns.
A system for producing polymer particles, the system comprising:
- a loop slurry polymerization reactor configured to polymerize monomer on a catalyst to form a plurality of polymer particles;
- a controller configured to determine an expected catalyst productivity based on expected polymerization conditions within the loop slurry polymerization reactor;
- one or more feed locations configured to direct the monomer and the catalyst into the loop slurry polymerization reactor, wherein the monomer comprises an olefin and wherein the catalyst comprises catalyst particles with an average catalyst particle size less than 50 microns and determined based on the expected catalyst productivity;
- and
- a continuous take off mechanism configured to remove the polymer particles from the loop slurry reactor, wherein 70 to 90 percent by weight of the polymer particles have an individual polymer particle size of 100 to 500 microns.
A system for producing polymer particles, the system comprising:
- a polymerization reactor configured to polymerize monomer on a catalyst to form a plurality of polymer particles;
- a controller configured to determine an expected catalyst productivity based on expected polymerization conditions within the polymerization reactor, and configured to calculate an average catalyst particle size based on the expected catalyst productivity and a target polymer particle size;
- one or more feed locations configured to direct the monomer and the catalyst into the polymerization reactor, wherein the monomer comprises an olefin and wherein the catalyst comprises catalyst particles, wherein 81 to 100 percent by weight of the catalyst particles are smaller than or equal to the average catalyst particle size;
- and
- a reactor outlet configured to remove the polymer particles from the polymerization reactor, wherein 70 to 90 percent by weight of the polymer particles have an individual polymer particle size of 100 to 500 microns.
Dependencies are inferred from the claim text.