A method and device for feeding a mud-like catalyst into a polymerization reactor

Abstract: The invention relates to a method a device for feeding a mud-like catalyst mixture into a polymerization reactor. The catalyst mixture is fed from a container (12) into a batching space (23,24) of a feeder (10) connected thereto, from which channel the catalyst mixture is further fed by batches into the polymerization reactor by means of the pressure of a medium fed into said feeder (10). In accordance with the invention, after each catalyst batch fed into the polymerization reactor, the medium is essentially totally removed from the batching space (23,24) of the feeder (10) by leading the medium via an outlet channel (19b) into a space between two valves (26, 28) of on/off type before filling the batching space (23,24) with a new catalyst batch. The invention also relates to a device for realizing the method.

Description: The invention relates to a method for feeding a mud-like catalyst mixture into a polymerization reactor, in which method the catalyst mixture is fed from a container into a batching space of a feeding device in contact with the container and from which container the catalyst mixture is further fed by batches into the polymerization reactor by means of a transfer medium. The invention also relates to a device for feeding a mud-like catalyst mixture by batches from the container of the polymerization reactor as a continuos process, which device comprises a four-way valve provided with a rotatable plug, in which are formed one or more through borings in such a way that the borings do not communicate with each other, and on the frame of which device are formed crosswise through holes, of which the first hole is formed of a first inlet channel connecting the container to the plug of the device, which channel on the opposite side of the plug continues as a first outlet channel out of the frame, and of which the second hole is formed of a second inlet channel connected to the catalyst-mixture transfer-medium feeding line, which channel on the opposite side of the plug continues as a second outlet channel connected to a reactor line entering the polymerization reactor. In many chemical reactions, e.g. in the polymerization of olefines, are used catalysts, which are fed into a polymerization reactor as a suspension in some hydrocarbon medium. In such processes, the catalyst mixture is usually fed from a separate feeding container as a mud-like catalyst suspension by means of a feeding or batching device into the polymerization reactor. Since polymerization processes are often continuous, it must be possible to continuously batch an exactly desired amount of the catalyst into the polymerization reactor. Since catalysts are often relatively thick mud-like mixtures, it sets high requirements for the operation and operational reliability of the batching device. Such a catalyst feeding system has previously been described e.g. in the US patent 3 227 312. It describes a feeding device comprising a rotatable plug valve, in which plug are made two through channels, which do not communicate with each other. As the plug rotates, each channel is alternately in contact with the catalyst feeding container, whereby it is filled with the catalyst mixture, and as the plug further rotates, the channel filled with the catalyst comes into a position, in which it communicates both with the polymerization reactor and a transfer medium block, and the medium coming from the block transports the catalyst from an inlet channel into the polymerization reactor. At the same time, another inlet channel has in turn rotated in such a way that it communicates with the catalyst feeding container and is thus filled with the catalyst mixture. The operating principle of the feeding device according to said US patent causes the fact that when the inlet channel comes into such a position that it communicates with the catalyst feeding container, it is simultaneously filled with pure transfer medium. This is also a disadvantage, since it further makes the flowing of the mud-like catalyst nurture into the inlet channel more difficult. As a consequence, the filling of the inlet channel slows down or it is filled only partially, and furthermore, the feeding capacity of the feeding device decreases, and at the same time, the production rate of the polymerization process decreases. The object of the present invention is to provide a method and a device, which avoid the disadvantage mentioned above. The inventive method is thus mainly characterized in that for speeding up the flowing of the catalyst mixture, the transfer medium is removed from the inlet channel by leading the medium into an outlet space communicating with the lower end of the batching channel and located between two successively operating outlet valves of on/off type, whereby, after the first outlet valve has opened and the second valve is closed, transfer medium transfers from the batching space of a plug valve by the volume of the outlet space between the valves, after which the second outlet valve opens for leading out the medium as the first valve closes. Furthermore, the object of the invention is to provide a device for feeding a mud-like catalyst mixture by batches from the container of the polymerization reactor as a continuos process, which device comprises a four-way valve provided with a rotatable plug, in which is formed one or more through borings in such a way that the borings do not communicate with each other, and on the frame of which device are formed crosswise through holes, of which the first hole is formed of a first inlet channel connecting the container to the plug of the device, which channel on the opposite side of the plug continues as a first outlet channel out of the frame, and of which the second hole is formed of a second inlet channel connected to the catalyst-mixture transfer-medium feeding line, which channel on the opposite side of the plug continues as a second outlet channel connected to a reactor line entering the polymerization reactor. The device according to the invention is mainly characterized in that an exhaust space formed by two valves of on/off type and a tube located therebetween is connected to said first outlet channel, whereby said valves operate sequentially so that when said borings come to said first outlet channel and the second valve is closed, the first valve opens and allows the catalyst transfer medium in the boring to flow into the tube, after which the first valve closes and the second valve opens for leading out the transfer medium. By means of the inventive method, the transfer medium can thus be removed from the batching channel, whereby the mud-like catalyst immediately descends in the empty inlet channel. The cycle of the feeding device can thus be essentially shortened and the feeding rate can thereby be increased. The inventive method preferably utilizes quickly opening and closing valves of on/off type, whose function is coupled to the rotational speed of the feeding-valve plug. When the plug rotates into such a position that the inlet channel filled with transfer medium comes to the block leading to the feeding container, the following sequence is started. The first exhaust valve opens first and allows the transfer medium to exit from the feeding-valve batching channel by the volume between the outlet valves, whereby the channel is simultaneously filled with the mud-like catalyst. The first exhaust valve then closes and the second exhaust valve opens and allows the pure transfer medium, now vaporizing at a lower pressure, to enter the transfer-medium outlet tube, along which it can be led e.g. into a torch. Finally, the second exhaust valve closes. The volume of the space between the exhaust valves is usufully dimensioned such that it corresponds to the volume of the inlet channel of the catalyst feeding valve, but said volume can also be slightly smaller or larger than this. The upper limit for said volume is mainly determined by the fact of whether the catalyst is allowed to travel out of the system along with the exhaust blowing and how much. The timing of the opening and closing moments of the exhaust valves naturally depends on the rotational frequency of the feeding valve. In the method according to the invention, the feeding plug can have one or more inlet channels, and in all cases, the capacity of the feeding device according to the US patent 3 227 312 can even be quadrupled. There are preferably at least two channels, but also several channels can be used. The invention is next described in detail with reference to the accompanying Figures 1 and 2 showing the catalyst feeding device and the catalyst feeder to be applied in the method according to the invention. In a catalyst feeding device 10 of Fig. 1 and 2, the catalyst mixture is fed along a feeding line 11 into a feeding container 12, which can also be provided with a mixing device (not shown). To a lower end 13 of the feeding container 12 is connected a catalyst feeder 16, with which the catalyst mixture is fed into a polymerization reactor. The catalyst mixture used in the system is mud-like, and it consists of small particles. The catalyst mixture can be e.g. chrome-based so that the chrome is absorbed on the surface of the particles. Accordingly, said catalyst mixture is run from the mixing container 12 into the feeder 16 partly by means of gravitational force and partly, if desired, also by means of overpressure maintained in the mixing container 12. The feeder 16 comprises, in a manner of speaking, a plug valve, which consists of a frame 17 of the feeder and a plug 18 fitted in a boring formed on the frame 17 and rotated by means of a shaft 30. On the frame 17 of the feeder are formed through and crosswise borings or channels in such a way that the first boring comprises a first inlet channel 19a connecting the lower end 13 of the mixing container 12 to the plug 18 of the feeder as well as a first outlet channel 19b coaxial with the first inlet channel 19a. The second boring in turn comprises a second inlet channel 20a, to which is connected a catalyst-mixture transfer-medium feeding tube 21, a second outlet channel 20b extending coaxially with the inlet channel 20a on the opposite side of the plug 18 of the feeder, which is connected to a reactor line 22 leading to the polymerization reactor. On the plug 18 of the feeder are in turn formed crosswise through borings 23,24, which are arranged on the plug 18 in such a way that the first boring 23 and the second boring 24 extend laterally with respect to the center axis of the plug 18 through the plug 18, but are yet not in contact which each other. When the plug 18 is thus rotated on the frame 17 of the feeder in a rotational direction A, the borings 23,24 formed on the plug 18 alternately connect with each other, on one hand, the first inlet channel 19a and and first outlet channel 19b, and on the other hand, the second inlet channel 20a and the second outler channel 20b. The plug 18 is fixed to a shaft (not shown) connected to a suitable actuator, by means of which the plug 18 is cyclically rotated during the process. Any suitable actuator can be used as an actuator. When the process in in operation, the plug 18 is thus continuously rotated by steps of 90°. In the figures of the drawing is shown a situation where the plug 18 has turned into a position, in which the first boring 23 in the plug 18 has turned to connect the first inlet channel 19a to the first outlet channel 19b. Correspondingly, the second boring 24 of the plug 18 is then in a position, in which is connects the second inlet channel 20a to the second outlet channel 20b. In the position shown in in Fig. 1, the catalyst mixture thus flows from the mixing container 12 via gravitational force from the first inlet channel 19a to the first boring 23 of the plug 18 so that the first boring 23 is entirely filled with the catalyst mixture. Similarly, in the situation shown in Fig. 1, medium is fed from the medium feeding line 21 to the second inlet channel 20a of the feeder, from which it passes through the second boring 24 of the plug 18 to the second outlet channel 20b and then further via the reactor line 22 to the polymerization reactor. Media typically used in such processes include propane, butane, hexane, pentane and the like. When the plug 18 is rotated from the situation shown in Fig. 1 in the rotational direction A by 90°, a situation occurs, where the first boring 23 of the plug 18 connects the second inlet channel 20a of the feeder to the second outlet channel 20b, and correspondingly, the second boring 24 connects the first inlet channel 19a to the first outlet channel 19b. Then, the medium fed from the medium feeding line 21 to the second inlet channel 20a runs the catalyst mixture in the first boring 23 along with it into the polymerization reactor. Similarly, a new batch of the catalyst then leaves from the mixing chamber 12 for the second boring 24 in the plug 18. In the solutions of prior art, a considerable problem related to the batching of the catalyst mixture into the polymerization reactor is formed by the fact that the borings 23,24 in the plug 18, which determine the quantity of the catalyst batch entering the polymerization reactor at every 90° turn, cannot freely and sufficiently rapidly be filled, since as the boring 23 or 24 turns to the first inlet channel 19a, the inlet channel 19a is filled with the catalyst-mixture transfer medium. In the solution according to the invention, this problem has been eliminated and solved as follows. An outlet tube 25 connected to the first outlet channel 19b is additionally provided with two valves 26,28 of on/off type, which are coupled to each other via a tube 27. The volume of the tube section 27 is approximately the same as that of the borings 23,24 formed on the plug 18. The valves 26 and 28 provide an essential improvent in the operation and the feeding capacity of the feeding device 10. When the plug 18 of the feeder is started to turn from the position shown in Fig. 1 in the direction of the arrow A, the first boring 23 of the plug is filled with the catalyst mixture and the second boring 24 is filled with the catalyst-mixture transfer medium. When the plug 18 turns into a position, in which the second boring 24 comes to the outlet channel 19b, the following sequence starts up. The valve 26 opens, whereby the medium in the boring 24 can transfer into the tube 27 located between the valves 26 and 28. Since the volume of the tube 27 approximately corresponds to the volume of the boring 24 and since the tube 27 is maintained at a low pressure, the tube 27 is filled with the medium and the boring 24 correspondingly empties of the medium. The valve 26 then closes and the valve 28 opens and lets the medium flow out into a tube 29, via which the medium transfers at a low pressure in an evaporated state e.g. into a torch. The valve 28 then closes and the sequence is repeated as the boring 23 comes to the outlet channel 19b. As mentioned above, the volume of the tube 27 between the valves 26 and 28 is dimensioned such that it corresponds to the volume of the inlet channels of the catalyst feeding valves, but said volume can also be slightly smaller or greater than this. The timing of the opening and closing moments of the valves 26 and 28 is naturally adjusted according to the revolutions of the plug 18. In the method and device according to the invention, the plug 18 can be provided with one or more borings, and in all cases, the capacity of the feeding device according to the US patent 3 227 312 can even be quadrupled. However, there are preferably two channels. The invention relates to a method a device for feeding a mud-like catalyst mixture into a polymerization reactor. The catalyst mixture is fed from a container (12) into a batching space (23,24) of a feeder (10) connected thereto, from which channel the catalyst mixture is further fed by batches into the polymerization reactor by means of the pressure of a medium fed into said feeder (10). In accordance with the invention, after each catalyst batch fed into the polymerization reactor, the medium is essentially totally removed from the batching space (23,24) of the feeder (10) by leading the medium via an outlet channel (19b) into a space between two valves (26, 28) of on/off type before filling the batching space (23,24) with a new catalyst batch. The invention also relates to a device for realizing the method.

Claims: A method for feeding a mud-like catalyst mixture into a polymerization reactor, in which method the catalyst mixture is fed from a container (12) into a batching channel (23,24) of a feeder (16) connected thereto, from which channel the catalyst mixture is fed by batches into the polymerization reactor by means of the pressure of a transfer medium of the catalyst fed into said feeder (16), characterized in that for speeding up the flowing of the catalyst mixture, the transfer medium is removed from the batching channel (23,24) by leading the medium into an outlet space communicating with the lower end of the batching channel and located between two successively operating outlet valves (26,28) of on/off type, whereby, after the first outlet valve (26) has opened and the second valve (28) is closed, transfer medium transfers from the batching space of a plug valve by the volume of the outlet space (27) between the valves (26,28), after which the second outlet valve (28) opens for leading out the medium as the first valve (26) closes. A method according to Claim 1, characterized in that the volume of the outlet space (27) between the valves (26,28) corresponds to the volume of the batching channel (23,24). A method according to Claim 1 or 2, characterized in that the opening and closing moment of the outlet valves (26,28) is adjusted according to the rotation of the plug valve. A method according to any of the preceding Claims, characterized in that the plug valve of the feeder (16) has two or more batching channels (23,24). A device for realizing the method according to any of the preceding Claims for feeding a mud-like catalyst mixture by batches from the container (12) of the polymerization reactor as a continuous process, which device (10) comprises a plug valve provided with a rotatable plug (18), in which is formed one or more through borings (23,24) in such a way that the borings do not communicate with each other, and on the frame of which plug valve are formed crosswise through holes, of which the first hole (19a,19b) is formed of a first inlet channel (19a) connecting the container (12) to the plug (18) of the feeding device (10), which channel on the opposite side of the plug (18) continues as a first outlet channel (19b) out of the frame, and of which the second hole (20a,20b) is formed of a second inlet channel (20a) connected to a catalyst-mixture transfer-medium feeding line (21), which channel on the opposite side of the plug (18) continues as a second outlet channel (20b) connected to a reactor line (22) entering the polymerization reactor, characterized in that an exhaust space formed by two valves (26,28) of on/off type and a tube (27) located therebetween is connected to said first outlet channel (19b), whereby said valves (26,28) operate sequentially so that when said borings (23,24) come to said first outlet channel (19b) and the second valve (28) is closed, the first valve (26) opens and allows the catalyst transfer medium in the boring (23,24) to flow into the tube (27), after which the first valve (26) closes and the second valve (28) opens for leading out the transfer medium. A device according to Claim 5, characterized in that the opening and closing moments of the valves (26,28) are regulated according to the rotation of the plug (18). A device according to Claim 5 or 6, characterized in that the plug (18) has two or more borings (23,24).

Inventors: SARANTILA KARI, TAKAKARHU JOUNI, SARANTILA, KARI, TAKAKARHU, JOUNI
Applicants: NESTE OY
Application year: 1991
Main classification: B01J3
IPC codes: B01J8, B01J3