Methods for Regulating Reactor Catalyst Flow Distribution During Olefin Polymerization

A flow control method, the method comprising:

• flowing a modified catalyst slurry into a gas-phase polymerization reactor through at least a first line connected to a first injection nozzle, a second line connected to a second injection nozzle, and a third line connected to a third injection nozzle,
• wherein each of the first, second, and third injection nozzles are in fluid communication with the gas-phase polymerization reactor;
• and
• independently regulating each of:
• a) a first flow rate of the modified catalyst slurry in the first line by at least partially opening or closing a first slurry flow valve in contact with the first line,
• b) a second flow rate of the modified catalyst slurry in the second line by at least partially opening or closing a second slurry flow valve in contact with the second line, or
• c) a third flow rate of the modified catalyst slurry in the third line by at least partially opening or closing a third slurry flow valve in contact with the third line.

A method comprising:

• obtaining a catalyst slurry comprising a supported catalyst, the supported catalyst comprising a support material, at least one catalyst compound, and at least one activator;
• obtaining a catalyst solution comprising a first catalyst compound that is the same as the catalyst compound already contained upon the supported catalyst or a second catalyst compound different from the first catalyst compound and not already contained upon the supported catalyst;
• contacting the catalyst slurry with the catalyst solution in a mixing unit to obtain a modified catalyst slurry from the mixing unit, the modified catalyst slurry comprising a modified supported catalyst incorporating at least a portion of the first catalyst compound or the second catalyst compound from the catalyst solution;
• flowing the modified catalyst slurry into a gas-phase polymerization reactor through at least a first line connected to a first injection nozzle, a second line connected to a second injection nozzle, and a third line connected to a third injection nozzle,
• wherein each of the first, second, and third injection nozzles are in fluid communication with the gas-phase polymerization reactor;
• and
• independently regulating each of one or more of:
• a) a first flow rate of the modified catalyst slurry in the first line by at least partially opening or closing a first slurry flow valve in contact with the first line,
• b) a second flow rate of the modified catalyst slurry in the second line by at least partially opening or closing a second slurry flow valve in contact with the second line, or
• c) a third flow rate of the modified catalyst slurry in the third line by at least partially opening or closing a third slurry flow valve in contact with the third line.