Source: http://www.google.com/patents/US8163246?dq=5,266,072
Timestamp: 2016-10-01 09:03:56
Document Index: 91780462

Matched Legal Cases: ['Application No. 200809160', 'Application No. 200809157', 'Application No. 200809158', 'Application No. 200809159', 'Application No. 200809161', 'Application No. 201004966', 'Application No. 201008798']

Patent US8163246 - Spouted-fluidized bed-type olefin polymerization reactor - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsAn olefin polymerization reactor according to the present invention comprises: a vertically extending cylinder; a decreasing diameter portion on the cylinder, having an inside diameter that decreases progressively downward, and having a gas inlet orifice at a bottom end thereof; and a plurality of through...http://www.google.com/patents/US8163246?utm_source=gb-gplus-sharePatent US8163246 - Spouted-fluidized bed-type olefin polymerization reactorAdvanced Patent SearchTry the new Google Patents, with machine-classified Google Scholar results, and Japanese and South Korean patents.Publication numberUS8163246 B2Publication typeGrantApplication numberUS 12/795,432Publication dateApr 24, 2012Filing dateJun 7, 2010Priority dateJun 8, 2009Fee statusPaidAlso published asCN101906178A, CN101906178B, DE102010023010A1, US20100311923Publication number12795432, 795432, US 8163246 B2, US 8163246B2, US-B2-8163246, US8163246 B2, US8163246B2InventorsHideki Sato, Hiroyuki OgawaOriginal AssigneeSumitomo Chemical Company, LimitedExport CitationBiBTeX, EndNote, RefManPatent Citations (90), Non-Patent Citations (37), Classifications (24), Legal Events (2) External Links: USPTO, USPTO Assignment, EspacenetSpouted-fluidized bed-type olefin polymerization reactor
US 8163246 B2Abstract
An olefin polymerization reactor according to the present invention comprises: a vertically extending cylinder; a decreasing diameter portion on the cylinder, having an inside diameter that decreases progressively downward, and having a gas inlet orifice at a bottom end thereof; and a plurality of through holes passing through from an outside surface towards an inside surface of the decreasing diameter portion. Inside a reaction zone enclosed by an inside surface of the decreasing diameter portion and an inside surface above the decreasing diameter portion of the cylinder, a spouted-fluidized bed or a spouted bed is formed.
From the standpoint of achieving high contact efficiency of particles and fluid, apparatuses using a flow called spouted-fluidized bed have been also studied (see Kishan B. Mathur et al. “SPOUTED BEDS”, ACADEMIC PRESS, INC. 1974, p. 263 to p. 264; Toshifumi Ishikura, Kagaku Kogaku Rombunshu (collection of theses, the Chemical Engineers) 1993, VOL. 19, No. 6, p. 1189 to p. 1192; Toshifumi Ishikura et al. Fukuoka Daigaku Kogaku Shuho (Collection of engineering theses, Fukuoka University, 1997, March, No. 58, p. 155 to p. 165). These apparatuses are provided with a gas introducing opening for forming a spouted bed and a dispersion plate for forming a fluidized bed. A technique of using a draft tube and a dispersion plate is described by Kishan B. Mathur et al. “SPOUTED BEDS”, ACADEMIC PRESS, INC. 1974, p. 263 to p. 264.
However, shipping of polyolefin materials is generally conducted by heating and melting the polyolefin particles and processing them into pellets. The major reason therefor is that the polyolefin particles obtained by polymerization have a small particle size and are unsuitable for handling during molding. Therefore, catalysts and processes have been developed that enable the production of large-diameter polyolefin particles that make it possible to omit the pelletizing process.
In this reactor, a spouted bed of polyolefin particles can be formed within the reaction zone by controlling an amount of an olefin-containing gas fed into the reaction zone so that an amount of the olefin-containing gas flowing around a spout portion formed in the center of the reaction zone is less than a minimum fluidization velocity. As used herein, “spouted bed” refers to a particle bed state characterized by the circulatory movement of particles, wherein there forms, in a particle bed composed of polyolefin particles (sometimes referred to below as simply “particles”) and under the action of an olefin-containing gas from the gas inlet orifice, a “spout” (or spout portion) which has a dilute particle concentration near the center axis of the cylinder and in which particles flow upward together with the gas, and at the same time there also forms at the periphery of the spout an annular structure where particles fall in a moving bed state under the influence of gravity.
FIG. 1 is a schematic structural view of an embodiment of the polyolefin production system according to the present invention;
FIG. 1 shows a polyolefin production system 100A according to the first embodiment. This production system 100A includes an olefin prepolymerization reactor 5 and an olefin polymerization reactor 10A which is connected as a subsequent stage to the olefin prepolymerization reactor 5.
The olefin polymerization catalyst used in the invention may be a known addition polymerization catalyst used in olefin polymerization. Illustrative examples include Ziegler-type solid catalysts formed by contacting a solid catalyst component containing titanium, magnesium, a halogen and an electron donor (referred to below as catalyst component “A”) with an organoaluminum compound component and an electron donor component; and metallocene-type solid catalysts prepared by supporting a metallocene compound and a cocatalyst component on a granular carrier. Combinations of these catalysts may also be used.
What is commonly referred to as a titanium/magnesium composite catalyst may be used as catalyst component “A” employed in the preparation of a Ziegler-type solid catalyst. This composite catalyst may be obtained by contacting a titanium compound, a magnesium compound and an electron donor such as the following.
Titanium compounds that may be used to prepare the catalyst component “A” are exemplified by titanium compounds having the general formula Ti(OR1)aX4-a (where R1 is a hydrocarbon group of 1 to 20 carbons, X is a halogen atom, and the letter a is a number such that 0≦a≦4). Illustrative examples include tetrahalogenated titanium compounds such as titanium tetrachloride; trihalogenated alkoxytitanium compounds such as ethoxytitanium trichloride and butoxytitanium trichloride; dihalogenated dialkoxytitanium compounds such as diethoxytitanium dichloride and dibutoxytitanium dichloride; monohalogenated trialkoxytitanium compounds such as triethoxytitanium chloride and tributoxytitanium chloride; and tetraalkoxytitanium compounds such as tetraethoxytitanium and tetrabutoxytitanium. These titanium compounds may be used singly or as combinations of two or more thereof.
Magnesium compounds that may be used to prepare catalyst component “A” are exemplified by magnesium compounds which have a magnesium-carbon bond or a magnesium-hydrogen bond and have a reducing ability, and magnesium compounds which lack a reducing ability. Illustrative examples of magnesium compounds which have a reducing ability include dialkylmagnesium compounds such as dimethylmagnesium, diethylmagnesium, dibutylmagnesium and butylethylmagnesium; alkylmagnesium halides such as butylmagnesium chloride; alkylalkoxymagnesium compounds such as butylethoxymagnesium; and alkylmagnesium hydrides such as butylmagnesium hydride. These magnesium compounds having a reducing ability may also be used in the form of a complex compound with an organoaluminum compound.
Illustrative examples of magnesium compounds which lack a reducing ability include dihalogenated magnesium compounds such as magnesium dichloride; alkoxymagnesium halides such as methoxymagnesium chloride, ethoxymagnesium chloride and butoxymagnesium chloride; dialkoxymagnesium compounds such as diethoxymagnesium and dibutoxymagnesium; and magnesium carboxylates such as magnesium laurate and magnesium stearate. These magnesium compounds which lack a reducing ability may be compounds which are synthesized, either in advance or at the time of catalyst component “A” preparation, by a known method from a magnesium compound having a reducing ability.
Electron donors that may be used to prepare catalyst component “A” include oxygen-containing electron donors such as alcohols, phenols, ketones, aldehydes, carboxylic acids, esters of organic or inorganic acids, ethers, acid amides and acid anhydrides; nitrogen-containing electron donors such as ammonia, amines, nitriles and isocyanates; and organic acid halides. Of these electron donors, the use of inorganic acid esters, organic acid esters and ethers is preferred.
Examples of methods for preparing catalyst component “A” include the following.
Of the above methods for preparing catalyst component “A”, methods (1) to (6) are preferred. These methods of preparation are generally all carried out in an inert gas atmosphere, such as nitrogen or argon.
In the preparation of catalyst component “A”, the titanium compound, organosilicon compound and ester compound are preferably used after dissolution or dilution in a suitable solvent. Illustrative examples of such solvents include aliphatic hydrocarbons such as hexane, heptane, octane and decane; aromatic hydrocarbons such as toluene and xylene; alicyclic hydrocarbons such as cyclohexane, methylcyclohexane and decalin; and ether compounds such as diethyl ether, dibutyl ether, diisoamyl ether and tetrahydrofuran.
In the preparation of catalyst component “A”, the temperature of the reducing reaction which uses an organomagnesium compound is generally from −50 to +70� C. From the standpoint of catalyst activity and cost, the temperature is preferably from −30 to +50� C., and more preferably from −25 to +35� C. The dropwise addition time for the organomagnesium compound, while not subject to any particular limitation, is generally from about 30 minutes to about 12 hours. Following completion of the reducing reaction, subsequent reactions may be carried out at a temperature of from 20 to 120� C.
In the preparation of catalyst component “A”, the reducing reaction may be carried out in the presence of a porous material such as an inorganic oxide or an organic polymer so as to allow the solid product to be impregnated into the porous material. Such porous materials preferably have a pore volume at a pore radius of from 20 to 200 nm of at least 0.3 ml/g and an average particle size of from 5 to 300 μm. Examples of porous inorganic oxides include SiO2, Al2O3, MgO, TiO2, ZrO2 and composite oxides thereof. Examples of porous polymers include polystyrene-based porous polymers such as polystyrene and styrene-divinylbenzene copolymers; polyacrylate ester-based porous polymers such as polyethyl acrylate, methyl acrylate-divinyl benzene copolymers, polymethyl methacrylate and methyl methacrylate-divinylbenzene copolymers; and polyolefin-based porous polymers such as polyethylene, ethylene-methyl acrylate copolymers and polypropylene. Of these porous substances, SiO2, Al2O3 and styrene-divinylbenzene copolymers are preferred.
In the preparation of a Ziegler solid catalyst, the organoaluminum compound component is used in an amount, per mole of titanium atoms in catalyst component “A”, of generally from 1 to 1,000 moles, and preferably from 5 to 800 moles. The electron donor component is used in an amount, per mole of titanium atoms in catalyst component “A”, of generally from 0.1 to 2,000 moles, preferably from 0.3 to 1,000 moles, and more preferably from 0.5 to 800 moles.
Catalyst component “A”, the organoaluminum compound component and the electron donor component may be brought into mutual contact before being fed to the multistage polymerization reactor, or may be separately fed to the multistage polymerization reactor, then contacted within the reactor. Alternatively, any two of these components may first be contacted with each other, and the remaining component subsequently brought into contact, or the respective components may be brought into mutual contact in a plurality of divided portions.
A production system 100B shown in FIG. 3 has an olefin prepolymerization reactor 5 and an olefin polymerization reactor 10B. The olefin polymerization reactor 10B differs from the above-described reactor 10A in having a draft tube T1 disposed within the reaction zone 25. By using the draft tube T1, it is possible to form within the reaction zone 25 a spouted bed that has excellent stability and can further reduce the pressure loss.
A preferred arrangement of the polyolefin production system which employs a bulk polymerization reactor as the olefin prepolymerization reactor and employs an ejector system as the transferring means is described in detail while referring to FIG. 4. The polyolefin production system 100C shown in FIG. 4 includes a bulk polymerization reactor 5 and an olefin polymerization reaction 10C having at the interior both top and bottom reaction zones 25.
The bulk polymerization reactor 5 polymerizes an olefin in a liquid phase containing an olefin polymerization catalyst, thereby forming polyolefin particles. The polyolefin particles formed in the bulk polymerization reactor 5 pass together with liquid olefin through a line L5, and are fed to the olefin polymerization reactor 10C. A nozzle 68 for feeding a slurry to the top reaction zone 25 is provided, as shown in FIG. 4, at a position lower than the powder level 85 of the spouted bed. When the slurry is fed into the reaction zone 25 from a position lower than the powder level 85, it is preferable to regulate the slurry feed rate so that the superficial velocity, following gasification, of the liquid olefin within the slurry does not exceed the minimum fluidization rate (Umf) of the polyolefin particles held within the reaction zone 25. By regulating the slurry feed rate in this way, it is possible to fully prevent the flow state of the spouted bed from becoming unstable with gasification of the liquid olefin inside the reaction zone 25. The “superficial velocity of the liquid olefin following gasification” as referred to herein is the value obtained by converting the volumetric flow rate of the liquid olefin fed to the olefin polymerization reactor to the volumetric flow rate following gasification, and dividing the latter by the cross-sectional area A of the olefin polymerization reactor cylinder (A=πD2/4, where DR is the inside diameter of the cylinder).
A production system 100D shown in FIG. 5 includes an olefin prepolymerization reactor 5 and an olefin polymerization reactor 10D. The olefin polymerization reactor 10D is used when particles are handled that can easily foam a stable spouted bed and differs from the above-described reactor 10A in that the partition plate 17, extension tube 40, and lines L31 a, L31 b are not provided within a cylinder 12D.
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No. 12/332,112.36Weickert et al., Chemie Ingenieur Technik, 2005, 77, No. 8, pp. 977-978.37Yokokawa, "Fluidizing characteristics of fluidized bed and spouted bed and their application", Journal of the Society of Powder Technology, vol. 21, No. 11, Nov. 1984, pp. 715-723.Classifications U.S. Classification422/131, 422/132, 422/134, 526/65International ClassificationB01J19/18, B01J19/00, B01J8/08, C08F2/01Cooperative ClassificationB01J8/1827, B01J8/0065, B01J8/34, C08F2/01, B01J8/44, B01J8/386, B01J8/28, B01J8/245European ClassificationB01J8/44, B01J8/00J6, B01J8/18G2, B01J8/28, B01J8/34, B01J8/24B, B01J8/38D2, C08F2/01Legal EventsDateCodeEventDescriptionJul 27, 2010ASAssignmentOwner name: SUMITOMO CHEMICAL COMPANY, LIMITED, JAPANFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SATO, HIDEKI;OGAWA, HIROYUKI;REEL/FRAME:024745/0873Effective date: 20100607Oct 7, 2015FPAYFee paymentYear of fee payment: 4RotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services