Source: http://www.google.com/patents/US7993593?dq=6,034,652
Timestamp: 2014-12-29 17:11:09
Document Index: 235411944

Matched Legal Cases: ['Application No. 2002', 'Application No. 200809160', 'Application No. 200809157', 'Application No. 200809158', 'Application No. 200809159', 'Application No. 200809160', 'Application No. 200809161', 'Application No. 201004966']

Patent US7993593 - Olefin polymerization reactor, polyolefin production system, and polyolefin ... - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsAn olefin polymerization reactor of the present invention includes a cylinder which extends vertically, and a decreasing diameter member which is formed on the cylinder, has an inside diameter that decreases progressively downward and has a gas inlet orifice at a bottom end thereof. A spouted bed is...http://www.google.com/patents/US7993593?utm_source=gb-gplus-sharePatent US7993593 - Olefin polymerization reactor, polyolefin production system, and polyolefin production processAdvanced Patent SearchPublication numberUS7993593 B2Publication typeGrantApplication numberUS 12/331,730Publication dateAug 9, 2011Filing dateDec 10, 2008Priority dateDec 11, 2007Also published asCN101456926A, DE102008061425A1, US20090149610Publication number12331730, 331730, US 7993593 B2, US 7993593B2, US-B2-7993593, US7993593 B2, US7993593B2InventorsHideki Sato, Hiroyuki OgawaOriginal AssigneeSumitomo Chemical Company, LimitedExport CitationBiBTeX, EndNote, RefManPatent Citations (83), Non-Patent Citations (30), Referenced by (2), Classifications (17), Legal Events (1) External Links: USPTO, USPTO Assignment, EspacenetOlefin polymerization reactor, polyolefin production system, and polyolefin production processUS 7993593 B2Abstract An olefin polymerization reactor of the present invention includes a cylinder which extends vertically, and a decreasing diameter member which is formed on the cylinder, has an inside diameter that decreases progressively downward and has a gas inlet orifice at a bottom end thereof. A spouted bed is formed inside a reaction zone enclosed by an inside surface of the decreasing diameter member and an inside surface of the cylinder above the decreasing diameter member.
In such cases, the formed particles have a poor structural uniformity. Other problems that tend to arise include higher catalyst costs, increased catalyst residues, and larger numbers of defects (referred to as �fish-eyes� owing to the similarity in shape to the eye of a fish) in molded articles obtained by molding multistage polymers prepared by polymerization in a plurality of reaction zones. Moreover, with complete mixing, when the polymerization of different lots is carried out by varying the polymerization conditions, because it takes time to completely discharge from the vessel the polyolefin particles that were polymerized prior to the change in conditions, a large amount of off-specification product ends up forming. One conceivable way to deal with this problem is to connect a plurality of continuously stirred reactors in series so as to create overall a plug flow pattern. However, the equipment costs associated with connecting a plurality of reactors in series are considerable.
SUMMARY OF THE INVENTION However, the process of Patent Publication No. 2,675,919, in which a plurality of zones are formed within a vessel in the horizontal direction, requires that stirring paddles or the like be provided within the vessel. This results in a more complicated construction, in addition to which a large amount of energy is required for agitate the particles. In the process of U.S. Pat. No. 5,235,009, wherein a plurality of fluidized beds are connected in series in the vertical direction, the need to provide a freeboard at each stage may result in an enormous reactor height. In Japanese Translation of PCT Application No. 2002-537420, which carries out polymerization in a single pass within a tubular reactor, the tube must be made extremely long to achieve a sufficient residence time.
In the spouted bed-type olefin polymerization reactor of the invention, an olefin-containing gas is made to flow upward at a high velocity from the gas inlet orifice at the bottom end of the decreasing diameter member and into a reaction zone that holds catalyst-containing polyolefin particles and where a particle bed is to be formed, thereby forming a spouted bed within the reaction zone. 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.
The �superficial velocity� of the liquid olefin following gasification 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 D is the inside diameter of the cylinder).
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view of an embodiment of the polyolefin production system according to the present invention;
The deflectors 20 and tubular baffles 30 are each attached to the cylinder 12 by supports (not shown). The supports have substantially no influence on gas flow and polyolefin flow. The cylinder 12, deflectors 20 and tubular baffles 30 may be made of, for example, carbon steels and stainless steels such as �SUS 304� and �SUS 316L�. As used herein, �SUS� refers to a stainless specification standardized by Japanese Industrial Standards (JIS). It is preferable to use �SUS 316L� when a catalyst which are high in corrosive ingredient (e.g., a halogen such as chlorine) is to be employed.
Ums = ⅆ P ⅆ B ( ⅆ A ⅆ B ) 1 / 3 2 gL S ( ρ S - ρ G ) ρ G � ( ρ G ρ AIR ) 0.2 ( 1 ) In this formula, dP is the particle diameter, ρS is the particle density, ρG is the gas density under the pressure and temperature conditions of the reaction zone, ρAIR is the density of air under room temperature conditions, and LS is the height of the spouted bed.
Ls MAX d B = ⅆ B ⅆ A { 0.218 + 0.005 ( ρ S - ρ G ) gd A ρ G u t u mf } ( 2 ) In this formula, ut is the terminal velocity of the particles, and umf is the minimum fluidization velocity.
EXAMPLES Example 1 A cylindrical cold model reactor made of transparent polyvinyl chloride and capable of forming two spouted beds inside the cylinder was furnished to investigate the residence time distribution in an olefin polymerization reactor according to the present invention. This unit had two tubular baffles of inverted conical shape with a gas inlet orifice therein, each of which was paired with a conical deflector, disposed vertically and coaxially within the cylinder.
Examples 2 to 9 Examples 2 to 9 below were carried out to investigate the relationship between the stability of a spouted bed formed in a reaction zone and the shape of the tubular baffle.
Example 2 A cylindrical cold model reactor made of transparent polyvinyl chloride and capable of forming a single spouted bed inside the cylinder was furnished for use. This reactor had, disposed within the cylinder, a single tubular baffle with an inverted conical shape having a gas inlet orifice and, paired with the baffle, a single deflector with a conical shape.
Example 3 Aside from setting the diameter dA of the gas inlet orifice at the bottom end of the tubular baffle to 75 mm instead of 100 mm, air was fed to the particle bed in the same way as in Example 2 and the flow state of the polypropylene particles was observed. In this example, the ratio dA/dB between the diameter dA of the gas inlet orifice and the cylinder inside diameter dB was 0.15. As in Example 2, an ordinary spouted bed flow state was observed in the present example.
Example 4 Aside from setting the diameter dA of the gas inlet orifice at the bottom end of the tubular baffle to 125 mm instead of 100 mm, air was fed to the particle bed in the same way as in Example 2 and the flow state of the polypropylene particles was observed. In this example, the ratio dA/dB between the diameter dA of the gas inlet orifice and the cylinder inside diameter dB was 0.25. As in Example 2, an ordinary spouted bed flow state was observed in the present example.
Example 5 Aside from feeding 7.1 m3/min of air to a particle bed composed of polypropylene particles having an average size of 900 μm instead of feeding 7.5 m3/min of air to a particle bed composed of polypropylene particles having an average size of 1,100 μm, air was fed to the particle bed in the same way as in Example 2 and the flow state of the polypropylene particles was observed. In this example, the ratio dA/dB between the diameter dA of the gas inlet orifice and the cylinder inside diameter dB was 0.2. As in Example 2, an ordinary spouted bed flow state was observed in the present example.
Example 6 Aside from setting the diameter dA of the gas inlet orifice at the bottom end of the tubular baffle to 75 mm instead of 100 mm, air was fed to the particle bed in the same way as in Example 2 and the flow state of the polypropylene particles was observed. In this example, the ratio dA/dB between the diameter dA of the gas inlet orifice and the cylinder inside diameter dB was 0.15. As in Example 2, an ordinary spouted bed flow state was observed in the present example.
Example 7 Aside from setting the diameter dA of the gas inlet orifice at the bottom end of the tubular baffle to 125 mm instead of 100 mm, air was fed to the particle bed in the same way as in Example 5 and the flow state of the polypropylene particles was observed. In this example, the ratio dA/dB between the diameter dA of the gas inlet orifice and the cylinder inside diameter dB was 0.25. As in Example 2, an ordinary spouted bed flow state was observed in the present example.
Example 8 Aside from setting the diameter dA of the gas inlet orifice at the bottom end of the tubular baffle to 50 mm instead of 100 mm, air was fed to the particle bed in the same way as in Example 2 and the flow state of the polypropylene particles was observed. In this example, the ratio dA/dB between the diameter dA of the gas inlet orifice and the cylinder inside diameter dB was 0.10. The formation of a spouted bed, although unstable, was confirmed in this example. That is, the spout moved off-center, forming at a position other than the center axis of the cylinder, which in turn resulted in a variation in the height of the particle bed peripheral to the spout. In addition, the spout forming position was observed to change irregularly over time.
Example 9 Aside from setting the diameter dA of the gas inlet orifice at the bottom end of the tubular baffle to 50 mm instead of 100 mm, air was fed to the particle bed in the same way as in Example 5 and the flow state of the polypropylene particles was observed. In this example, the ratio dA/dB between the diameter dA of the gas inlet orifice and the cylinder inside diameter dB was 0.10. The formation of a spouted bed, although unstable, was confirmed in this example. That is, the spout moved off-center, forming at a position other than the center axis of the cylinder, which in turn resulted in a variation in the height of the particle bed peripheral to the spout. In addition, the spout forming position was observed to change irregularly over time.
Examples 10 to 13, and Comparative Examples 1 to 3 The polyolefin production process carried out in Examples 10 to 12 of the invention included a step (Polymerization Step II) in which propylene homopolymerization was carried out using a spouted bed reactor. The polyolefin production process carried out in Comparative Examples 1 to 3 included a step (Polymerization Step II) in which propylene homopolymerization was carried out using a fluidized bed reactor instead of a spouted bed reactor. The polyolefin production process carried out in Example 13 of the invention included a step (Polymerization Step III) in which propylene-ethylene copolymerization was carried out using a spouted bed reactor. In Examples 10 to 13 and Comparative Examples 1 to 3, the physical properties of the polymer were measured and evaluated as described below.
The ethylene unit content was determined by the IR spectrum method, in accordance with IR spectrum measurement described on page 619 of Kōbunshi handobukku [The polymer handbook] (1995, Kinokuniya Shoten). As used herein, �ethylene unit� refers to structural units which originate from ethylene.
The polymer was fed to a T-die film-forming machine (manufactured by Tanabe Plastics Kikai; T-die width, 100 mm) equipped with a single-screw extruder having a screw diameter of 20 mm, and a 50 μm thick sheet was manufactured at a temperature of 210� C. The resulting sheet was placed on the platen of a scanner (GT-9600), manufactured by Seiko Epson Corporation; resolution, 1600 dpi). Next, a Hansa Hard Chrome Ferrotype Plate (produced under this brand name by Omiya Shashin Yohin KK) was placed over the sheet with the mirror-finished side of the plate facing the sheet. Setting the scanner resolution to 900 dpi and the tonal gradations for each pixel to 8 bits, an image of the sheet was entered into the computer as a black-and-white image and saved in a bitmapped format. This image was digitized using image analysis software (produced by Asahi Kasei Engineering Corporation under the brand name �A-zo kun��). Fisheyes were recognized as areas that are brighter than their surroundings. Because the fisheyes were of indefinite shape, the size of each fisheye was equated to the diameter of a circle of the same surface area, and the number of fisheyes having a diameter of 200 μm or more was determined. The fisheye count was the number of such fisheyes per 100 cm2 of the sheet.
Example 10 Prepolymerization
Example 11 Polymerization Step I (Propylene Homopolymerization Using Slurry Polymerization Reactor)
Example 12 Polymerization Step I (Polypropylene Homopolymerization Using Slurry Polymerization Reactor)
Comparative Example 1 Polymerization Step I (Polypropylene Homopolymerization Using Slurry Polymerization Reactor)
Comparative Example 2 Polymerization Step I (Polypropylene Homopolymerization Using Slurry Polymerization Reactor)
Comparative Example 3 Polymerization Step I (Polypropylene Homopolymerization Using Slurry Polymerization Reactor)
Example 13 Polymerization Step I-1 (Propylene Homopolymerization Using Slurry Polymerization Reaction)
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No. 12/332,055.29Weickert et al., "New Reactor Concepts for the Gas-Phase Polymerization of Olefins," Chemie Ingenieur Technik, vol. 77, No. 8, 2005, pp. 977-978.30Yokokawa, "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.Referenced byCiting PatentFiling datePublication dateApplicantTitleUS8435452 *Feb 17, 2011May 7, 2013Exxonmobil Research And Engineering CompanyCirculating fluid bed reactor with improved circulationUS20110206563 *Feb 17, 2011Aug 25, 2011Exxonmobil Research And Engineering CompanyCirculating fluid bed reactor with improved circulation* Cited by examinerClassifications U.S. Classification422/131, 526/68, 422/134, 526/348, 526/65International ClassificationB01J19/00, C08F2/00, B01J19/18, C08F210/00Cooperative ClassificationB01J8/245, B01J2208/00283, C08F210/06, B01J2208/00292, B01J2208/0007, C08F10/00, B01J2208/00274European ClassificationC08F10/00Legal EventsDateCodeEventDescriptionJan 30, 2009ASAssignmentOwner name: SUMITOMO CHEMICAL COMPANY, LIMITED, JAPANFree format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SATO, HIDEKI;OGAWA, HIROYUKI;REEL/FRAME:022179/0271Effective date: 20081209RotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services©2012 Google