US 5,977,251 A · Non-adiabatic olefin solution polymerization

Abstract

A solution polymerization system for polymerizing a olefin monomer by reacting the monomer with catalyst and solvent has been invented. The system in one aspect including a flow loop with a product polymer outlet, the flow loop forming a recycling reactor, a catalyst inlet on the flow loop through which catalyst and solvent flow into the flow loop, a monomer inlet on the flow loop through which monomer and solvent flow into the flow loop and, with the catalyst, form a reactant materials stream, a first heat exchanger on the flow loop for receiving the reactant materials stream and any formed polymer and for removing heat of reaction or polymerization from the flow loop, and pump apparatus for pumping the reactant materials stream and formed polymer in the flow loop and from the first heat exchanger to the product polymer outlet. In one aspect, the system includes at least one additional heat exchanger on the flow loop for receiving the reactant materials stream and formed polymer and for removing heat of reaction or polymerization from the flow loop, the pump apparatus pumping formed polymer and remaining reactant materials to the product polymer outlet, and a portion of the formed polymer and remaining reactant materials flowing out from the product polymer outlet and the remainder recycling through the flow loop. In one aspect systems and methods according to the present invention are used to make polyethylene.

Claims62

Dependent claims

A nonadiabatic solution polymerization process for making a polymer comprising ethylene and at least one other monomer in at least one reactor stream of at least one reactor with catalyst and solvent, the process comprising:

(A) at least one flow loop which forms the at least one reactor, the at least one reactor having a reactor volume and the at least one flow loop having:
(1) at least one product outlet,
(2) at least one catalyst inlet through which catalyst flows into the at least one flow loop,
(3) at least one monomer inlet through which monomer flows into the at least one flow loop and, with catalyst and solvent, forms a reaction stream,
(4) at least one heat exchange apparatus which receives the reaction stream and polymer formed therein, and which removes heat of reaction or polymerization from nthe at least one flow loop, and
(5) at least one pump apparalls for pumping the reaction stream and polymer around the at least one flow loop,
(B) a portion of the reaction stream and polymer exiting the at least one flow loop through the at least one product outlet, and
(C) the at least one heat exchange apparatus removing heat of reaction or polymerization from the polymer and reaction stream at a rate of at least 400 Btu/hour.multidot.cubic foot.multidot..degree.F. (7.4 kW/m.sup.3 .multidot..degree.K),
wherein the polymer is characterized as being homogeneously branched as indicated by a comonomer distribution branching index (CDBI) greater than 50 percent, as determined using a temperature rising elution fractionation technique, and
wherein the at least one flow loop has a flow loop volume of greater than or equal to 1 cubic meter and polymer is produced at a rate of at least 5 pounds per hour per gallon of flow loop volume.

7 more elements

A nonadiabatic solution polymerization process for making a polymer comprising ethylene and at least one other monomer in a reactor stream of two or more reactors with catalyst and solvent, the process comprising:

(A) a first flow loop which forms a first reactor, the first reactor having a first reactor volume and the first flow loop having:
(i) at least one first product outlet,
(ii) at least one first catalyst inlet through which catalyst flows into the first flow loop,
(iii) at least one first monomer inlet through which monomer flows into the first flow loop and, with catalyst and solvent, forms a first reaction stream,
(iv) at least one first heat exchange apparatus which receives the first reaction stream and first polymer formed therein, and which removes heat of reaction or polymerization from the first flow loop, ad
(v) at least one first punp apparatus for pumping the first reaction stream and first polymer in the first flow loop from the at least one first heat exchange apparatus to the at least one first product outlet, and
(B) a second flow loop which forms a second reactor, the second reactor having a second reactor volume and the second flow loop having:
(i) at least one second product outlet,
(ii) at least one second catalyst inlet through which catalyst flows into the second flow loop,
(iii) at least one second monomer inlet through which monomer flows into the second flow loop and, with catalyst and solvent, forms a second reaction stream,
(iv) at least one second heat exchange apparatus which receives the second reaction stream and second polymer formed therein, and which removes heat of reaction or polymerization from the second flow loop, and
(v) at least one second pump apparatus for pumping the second reaction stream and second polymer in the second flow loop from the at least one second heat exchange apparatus to the second product outlet, and
(C) the at least one first heat exchange apparatus and the at least one second heat exchange apparatus removing total heat of reaction or polymerization from the reactor streams at a rate of at least 400 Btu/hour.multidot.cubic foot.multidot..degree.F. (7.4 kW/m.sup.3 .multidot..degree.K),
(D) the second flow loop having at least one product inlet into which flows the first polymer and a portion of the first reactor stream from the at least one first product outlet of the first flow loop, and
(E) a portion of first polymer, second polymer, first reaction stream and second reaction stream exiting the second flow loop through the at least one second product outlet
wherein the polymer is characterized being homogeneously branched as indicated by a comonomer distribution branching index (CDBI) greater than 50 percent, as determined using a temperature rising elution fractionation technique, and
wherein the at least one flow loop has a flow loop volume of greater than or equal to 1 cubic meter and polymer is produced at a rate of at least 5 pounds per hour per gallon of flow loop volume.

14 more elements

A nonadiabatic solution polymerization process for making a polymer comprising ethylene and at least one other monomer, the process comprising

feeding monomer into at least one flow loop, the at least one flow loop forning at least one reactor,
feeding catalyst into the at least one flow loop,
feeding solvent into the at least one flow loop,
the monomer, catalyst, and solvent forming a reaction stream in which a polymerization reaction of the monomer to the polymer occurs giving off heat of reaction or polymerization,
flowing the reaction stream to at least one heat exchange apparatus, wherein heat of reaction or polymerization is removed from the polymer and reaction stream at a rate of at least 400 Btu/hour.multidot.cubic foot.multidot..degree.F. (7.4 kW/m.sup.3 .multidot..degree.K), and
a portion of the polymer and reaction stream exiting the at least one flow loop through a product outlet and the remainder thereof recycling back through the at least one flow loop
wherein the polymer is characterized being homogeneously branched as indicated by a comonorner distribution branching index (CDBI) greater than 50 percent, as determined using a temperature rising elution fractioration technique, and
wherein the at least one flow loop has a flow loop volume of greater than or equal to 1 cubic meter and polymer is produced at a rate of at least 5 pounds per hour per gallon of flow loop volume.

5 more elements

A nonadiabatic solution polvmerization process for making a polymer comprising ethylene and at least one other monomer, the process comprising

feeding monomer into a first flow loop, the first flow loop comprising a first recycling reactor having a first reactor volume,
feeding catalyst into the first flow loop,
feeding solvent into the first flow loop,
the monomer, catalyst, and solvent forming a first reaction stream in which a polymerization reaction of the monomer to a first polymer occurs giving off heat of reaction or polymerization,
flowing the first reaction stream to first heat exchange apparatus, wherein heat of reaction or polymerization is removed from the first polymer and first reaction stream at a rate of at least 400 Btu/hour.multidot.cubic foot.multidot..degree.F.,
at least a portion of the first polymer and first reaction stream exiting the first flow loop through a first product outlet,
feeding monomer into a second flow loop, the second flow loop comprising a second recycling reactor having a second reactor volume,
feeding catalyst into the second flow loop,
feeding solvent into the second flow loop,
the monomer, catalyst, and solvent forming a second reaction stream in which a polymerization reaction of the monomer to a second polymer like the first polymer occurs giving off heat of reaction or polymerization,
flowing the reaction stream to second heat exchange apparatus, wherein heat of reaction or polymerization is removed from the second polymer and second reaction stream at a rate of at least 400 Btu/hour.multidot.cubic foot.multidot..degree.F., and
at least a portion of the second polymer and second reaction stream exiting the second flow loop through a second product outlet
wherein the polymer is characterized being homogeneously branched as indicated by a comonomer distribution branching (CDBI) index greater than 50 percent, as determined using a temperature rising elution fractionation technique, and
wherein the at least one flow loop has a flow loop volume of greater than or equal to 1 cubic meter and polymer is produced at a rate of at least 5 pounds per hour per gallon of flow loop volume.

11 more elements

Dependencies are inferred from the claim text.

Non-adiabatic olefin solution polymerization

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Non-adiabatic olefin solution polymerization

Life of this patent

Abstract

Claims62