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US 2024/0400729 A1Published application
Ethylene polymerization processes and reactor systems for the production of multimodal polymers using combinations of a loop reactor and a fluidized bed reactor
AssigneeChevron Phillips Chemical Company LP
InventorsJoel A. Mutchler, Eric J. Netemeyer, Joseph A. Curren, Michael H. Treptau, Kenneth A. Dooley, Jeffrey S. Lowell, Jeffrey S. Fodor, Scott E. Kufeld
Life of this patent
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Abstract
Polymerization processes and reactor systems for producing multimodal ethylene polymers are disclosed in which at least one loop reactor and at least one fluidized bed reactor are utilized. Configurations include a loop reactor in series with a fluidized bed reactor and two loop reactors in series with a fluidized bed reactor.
Claims27
1-23. (canceled)
A process for producing a multimodal ethylene polymer, the process comprising:
- (i) contacting a catalyst composition with ethylene, an optional first olefin comonomer, and optional hydrogen in an inert hydrocarbon diluent in a first loop reactor under slurry or supercritical polymerization conditions to produce a first ethylene polymer;
- (ii) discharging a first reactor effluent containing the first ethylene polymer from the first loop reactor and introducing the first reactor effluent into a second loop reactor;
- (iii) contacting the first reactor effluent with ethylene, an optional second olefin comonomer, and optional hydrogen in the second loop reactor under slurry or supercritical polymerization conditions to produce a second ethylene polymer;
- (iv) discharging a second reactor effluent containing the second ethylene polymer from the second loop reactor;
- (v) separating a light fraction comprising hydrogen from the second reactor effluent to form an intermediate material containing the second ethylene polymer, wherein hydrogen is present in step (i), or step (iii), or both;
- and
- (vi) contacting the intermediate material containing the second ethylene polymer with ethylene and an optional third olefin comonomer in an inert gas and/or hydrocarbon in a fluidized bed reactor under gas phase polymerization conditions to produce the multimodal ethylene polymer;
- wherein:
- from 5 to 30 wt. % of the multimodal ethylene polymer is produced in the first loop reactor;
- and
- from 30 to 60 wt. % of the multimodal ethylene polymer is produced in the fluidized bed reactor.
8 more elements
A polymerization reactor system for producing a multimodal ethylene polymer, the system comprising:
- (a) a first loop reactor configured to contact a catalyst composition with ethylene, an optional first olefin comonomer, and optional hydrogen in an inert hydrocarbon diluent under slurry or supercritical polymerization conditions to produce a first ethylene polymer;
- (b) a second loop reactor configured to contact a first reactor effluent containing the first ethylene polymer with ethylene, an optional second olefin comonomer, and optional hydrogen under slurry or supercritical polymerization conditions to produce a second ethylene polymer;
- (c) a transfer line configured to withdraw the first reactor effluent containing the first ethylene polymer from the first loop reactor and to introduce the first reactor effluent into the second loop reactor;
- (d) a second discharge line configured to withdraw a second reactor effluent containing the second ethylene polymer from the second loop reactor;
- (e) a separator configured to remove a light fraction comprising hydrogen from the second reactor effluent to form an intermediate material containing the second ethylene polymer, wherein hydrogen is present in the first loop reactor, the second loop reactor, or both;
- and
- (f) a fluidized bed reactor configured to contact the intermediate material containing the second ethylene polymer with ethylene and an optional third olefin comonomer in an inert gas and/or hydrocarbon under gas phase polymerization conditions to produce the multimodal ethylene polymer;
- wherein:
- the first loop reactor is configured to produce from 5 to 30 wt. % of the multimodal ethylene polymer;
- and
- the fluidized bed reactor is configured to produce from 30 to 60 wt. % of the multimodal ethylene polymer.
8 more elements
A process for producing a multimodal ethylene polymer, the process comprising:
- (I) contacting a catalyst composition with ethylene, an optional first olefin comonomer, and optional hydrogen in an inert hydrocarbon diluent in a first loop reactor under slurry or supercritical polymerization conditions to produce a first ethylene polymer;
- (II) discharging a first reactor effluent containing the first ethylene polymer from the first loop reactor and introducing the first reactor effluent into a second loop reactor;
- (III) contacting the first reactor effluent with ethylene, an optional second olefin comonomer, and optional hydrogen in the second loop reactor under slurry or supercritical polymerization conditions to produce a second ethylene polymer;
- (IV) discharging a second reactor effluent containing the second ethylene polymer from the second loop reactor, wherein hydrogen is present in step (I), or step (III), or both;
- and
- (V) contacting the second reactor effluent containing the second ethylene polymer with ethylene and an optional third olefin comonomer in an inert gas and/or hydrocarbon in a fluidized bed reactor under gas phase polymerization conditions to produce the multimodal ethylene polymer;
- wherein:
- from 5 to 30 wt. % of the multimodal ethylene polymer is produced in the first loop reactor;
- and
- from 30 to 60 wt. % of the multimodal ethylene polymer is produced in the fluidized bed reactor.
7 more elements
A polymerization reactor system for producing a multimodal ethylene polymer, the system comprising:
- (A) a first loop reactor configured to contact a catalyst composition with ethylene, an optional first olefin comonomer, and optional hydrogen in an inert hydrocarbon diluent under slurry or supercritical polymerization conditions to produce a first ethylene polymer;
- (B) a second loop reactor configured to contact a first reactor effluent containing the first ethylene polymer with ethylene, an optional second olefin comonomer, and optional hydrogen under slurry or supercritical polymerization conditions to produce a second ethylene polymer;
- (C) a transfer line configured to withdraw the first reactor effluent containing the first ethylene polymer from the first loop reactor and to introduce the first reactor effluent into the second loop reactor;
- (D) a second discharge line configured to withdraw a second reactor effluent containing the second ethylene polymer from the second loop reactor, wherein hydrogen is present in the first loop reactor, the second loop reactor, or both;
- and
- (E) a fluidized bed reactor configured to contact the second reactor effluent containing the second ethylene polymer with ethylene and an optional third olefin comonomer in an inert gas and/or hydrocarbon under gas phase polymerization conditions to produce the multimodal ethylene polymer;
- wherein:
- the first loop reactor is configured to produce from 5 to 30 wt. % of the multimodal ethylene polymer;
- and
- the fluidized bed reactor is configured to produce from 30 to 60 wt. % of the multimodal ethylene polymer.
7 more elements
Dependencies are inferred from the claim text.