Patent Description:
The use of polymers and/or copolymers of alpha-olefins to reduce the effect of friction ("drag") experienced by a liquid hydrocarbon flowing through a hydrocarbon transportation pipeline is well-known in the art. Reduction of the drag decreases the amount of energy needed to accomplish such flow, and therefore also decreases the costs associated with pumping. These materials, often called drag reducing agents (DRAs), can take various forms, including certain polymers in oil soluble suspensions, emulsions, pellets, gels, microfine powders and particulate slurries, for example comprising aqueous, organic or mixed aqueous / organic solvents. In some cases, the DRA may comprise a 'true' solution in an appropriate carrier solvent (e.g. dilute polymer solution product, produced in a solution polymerisation process). However, particulate slurries that comprise ground polymers are often the least expensive form.

The polymers that are most commonly used in preparing DRAs are poly(alpha-olefins) of carbon chain lengths ranging from <NUM> to about <NUM>. Typically these polymers are prepared using Ziegler-Natta catalysts and frequently also co-catalysts such as alkyl aluminium compounds. These polymerization reactions tend to be very efficient, producing relatively high yield when carried out in bulk. However, they also tend to be highly exothermic. The exotherm itself creates problems which reduce the usefulness of the product if the exotherm is not effectively managed. These problems include, but are not necessarily limited to, a substantial reduction in the polymer molecular weight. This can substantially reduce the efficacy of the polymer in a drag reducing agent formulation.

Various different types of apparatus have been described for producing polymers and/or copolymers of alpha-olefins as described below.

<CIT> and <CIT> describe the preparation and use of non-crystalline high molecular weight hydrocarbon soluble drag reducing polymers. The documents describe suitable polymerization reaction vessels as being polymeric bottles and bags. It is stated the invention there described has been demonstrated with bottles and bags containing five to seven layers, including a water impervious polyolefin such as polypropylene, polyethylene, polybutylene, a bonding polymer, and ethylene vinyl alcohol copolymer oxygen barrier, another bonding polymer, and externally coated with polyethylene, polypropylene or polybutylene. Use of polyethylene terephthlate as an additional layer to add reactor strength at high temperatures is stated to be most preferred. One disadvantage of use of the bottle and bag described is that the produced poly(alpha-olefin) polymer is extremely adherent to the walls of the reactor vessels. As a result, the polymeric vessels cannot be separated from the poly(alpha-olefin) polymer. Instead, the bottles or bags are ground together with the polymer in forming the drag reducing material. This is, however, disadvantageous and undesirable - the material of the bottles or bag may contaminate downstream processes or products, for example within oil refineries. When contamination reaches the refined fuel, adverse effects such as filter blockages may occur in the end fuel application.

<CIT>, <CIT>, <CIT> and <CIT> describe polymerization reactors for creating drag-reducing polymers. The reactors are said to address the problem of removal of heat from the DRA polymerization reactor without the addition of cooling additives. The solution to the problem involves use of a reactor which includes a reservoir which incorporates an array of plates which define a heat exchanger. In one embodiment, seventeen, <NUM> feet heat exchanger plates are spaced apart by <NUM><NUM>/<NUM> inches. Disadvantageously, it is difficult using the apparatus to achieve consistent product quality, due to the dimensions and it may be difficult to separate the polymer from the heat exchanger plates.

<CIT> describes continuous polymerization and ambient grinding methods for polyolefin drag reducing agents. In one embodiment, there is described a continuous polymerization method which involves a "form, fill and seal" packaging process. Polymerization apparatus may comprise a continuous stirred tank reactor (CSTR) where raw materials (e.g. monomers. and catalysts) are continuously charged, allowed an appropriate dwell or residence time in the reactor system, such that adequate molecular weight or viscosity is sustained and, subsequently, discharged in a continuous fashion to a "form, fill and seal" packaging device. The packaging device may form bags which serve as temporary and isolated reactor vessels which are collected, kept in the presence of an inert atmosphere and reactants allowed to polymerise to high conversion.

<CIT> discloses a method of preparing polymers which are drag reducing agents. The method comprises allowing a polymerization mixture to polymerize in at least one closed reaction chamber configured as a linear void space with a linear axis and a cross-section and first and second ends, where the linear void space is surrounded by a chamber wall having an inner chamber surface and an outer heat exchange surface. Coolant is passed over the outer heat exchange surface to remove heat therefrom. The ends of the reaction chamber are opened and essentially all of the polymer is removed from each reaction chamber with a harvesting plunger. The harvesting plunger travels along the linear axis of the void space from the first end to the second end thereof. However, use of harvesting plungers is impractical as apparatus comprising such plungers is expensive to manufacture, the plungers are not very effective for removing the solid polymer from the reaction chambers and, furthermore, cleaning of the apparatus ready for recharging of the reaction chambers is time-consuming and difficult.

It is desirable for apparatus for use in chemical reactions to be capable of assembly and disassembly in an efficient cost-effective manner so that it can largely be re-used in multiple sequential processes for batch-wise production of products. It is an object of preferred embodiments of the present invention to address the above-described problems.

It is an object of preferred embodiments of the invention to provide a simple and/or advantageous method of assembling apparatus for use in chemical reactions, preferably polymerisation reactions for producing drag reducing polymers.

It is an object of the preferred embodiments of the invention to provide a simple and/or advantageous apparatus and/or components thereof for use in chemical reactions, preferably polymerisation reactions for producing drag reducing polymers.

According to a first aspect of the invention, there is provided a method of assembling apparatus for containing reagents for a chemical reaction, the method comprising:.

By use of the method, the second end of the receptacle may be arranged in position, whilst minimising folds in the receptacle at or adjacent the second end; such folds might otherwise undesirably contain air and/or oxygen which could be detrimental to a reaction which may be undertaken in the apparatus. In a preferred embodiment, the apparatus is for undertaking a polymerisation reaction for producing a drag reducing polymer, suitably as herein described.

Said receptacle is preferably inherently not self-supporting. It is preferably flaccid when not containing a solid or fluid (eg reagents or polymer) and/or unless inflated or otherwise supported by external means as described herein.

Said receptacle preferably comprises a plastics material, for example a plastics film material which is arranged to define said receptacle. Said film material may have a thickness of at least <NUM>, suitably at least <NUM>, preferably at least <NUM>. The thickness of the film material may be less than <NUM>, preferably less than <NUM>, more preferably less than <NUM>. The thickness of the film material may be between <NUM> and <NUM>, preferably between <NUM> and <NUM>.

The internal wall area of the receptacle may be defined as the area of the receptacle which contains said polymer. Suitably, at least <NUM>%, preferably at least <NUM>%, more preferably at least <NUM>%, especially about <NUM>% of the internal wall area is defined by a said plastics film material having a thickness in the range defined.

The internal wall area of the receptacle as described is preferably defined by a plastics film material which consists of a single layer. Thus, the receptacle preferably does not comprise a laminate and/or a multi-ply material. Said internal wall area of the receptacle preferably has a substantially smooth surface.

An external wall area of the receptacle, being the wall area of the receptacle on an opposite side of the film material to that of the internal wall area, preferably has a substantially smooth surface as described for that of the internal wall area. Said internal wall area and said external wall area preferably consist of identical materials and, preferably, represent opposing surfaces of the same material.

Preferably, substantially the entirety of said receptacle comprises said plastics material, more preferably said plastics film material as described.

As described, said receptacle preferably comprises a plastics material, for example a plastics film material. Suitably, at least <NUM> wt%, preferably at least <NUM> wt%, more preferably <NUM> wt% of said receptacle is made up of said plastics material.

Said plastic material is suitably sufficiently strong and inert to withstand a polymerisation reaction described herein and not to adhere significantly to the polymer as it is forming. It is also preferably relatively cheap, so it can be discarded after use. Said plastic material is preferably heat sealable. It is preferably a thermoplastic polymer. It is preferably chemically compatible with the reagents used and polymer produced in the polymerisation reaction. Said plastic material preferably comprises optionally-substituted, preferably unsubstituted, alkylene (eg ethylene) repeat units which may be components of a homopolymer or copolymer. Said plastic material preferably comprises an optionally-substituted, preferably unsubstituted, polyolefin polymer, such as a polyalkylene polymer, for example polyethylene.

As described, said receptacle suitably includes a first end and a second end which are spaced apart along the elongate extent of the receptacle. Said first end is preferably a closed end and, more preferably, is substantially permanently closed - i.e. it is preferably not openable, except by, for example, destruction of the receptacle. Said first end preferably includes a sealed, for example a heat sealed region, suitably whereby opposing walls of the receptacle have been secured together, for example heat bonded together, thereby to define the closed end. The length of the receptacle is suitably the linear distance between said first end and said second end.

In the context of the present specification and unless the context otherwise requires, the diameter of the elongate receptacle refers to the longest straight line passing from one side of the cross-section of the receptacle to an opposite side, when the receptacle is in a distended (eg inflated) state and/or when it is configured to define its maximum cross-sectional area.

In the context of an elongate receptacle having a substantially symmetrical cross-sectional shape (eg having a substantially circular cross-section), the diameter of the elongate receptacle refers to a straight line passing from one side to an opposite side of the receptacle, through the centre of the cross-section, when the receptacle is in a distended (eg inflated) state and/or when it is configured to define its maximum cross-sectional area.

Preferably, the diameter of the elongate receptacle is substantially constant for at least <NUM>% (preferably at least <NUM>% or <NUM>%) of the distance from the first end towards said second end. In a preferred embodiment, a region (e.g. said mouth) of the receptacle adjacent said second end diverges (or is suitably splayed) so an opening of the receptacle at said second end has a slightly greater diameter than a region of the receptacle inwards of the second end. As described, such an arrangement facilitates securement and sealing of the second end in position in an apparatus in which the polymer may be produced in a way which minimises creation of air gaps in use and/or forms a leak tight seal.

The diameter of the internal volume of the receptacle (when in an extended state) may be in the range <NUM> to <NUM>) across its entire extent. When the second end defines a mouth at said second end which has a greater diameter and/or diverges as described, the maximum diameter of the divergent region may be up to <NUM>% greater than the diameter of the receptacle upstream of the divergent region. The length of the internal volume of the receptacle may be in the range <NUM> to <NUM>. The internal volume of the receptacle may be in the range <NUM><NUM> to <NUM><NUM>. Preferably, said diameter of the receptacle (suitably across at least <NUM>% of the length of the receptacle) is less than <NUM>. It is more preferably less than <NUM> (suitably across at least <NUM>% of the length of the receptacle). It may be at least <NUM> or at least <NUM> (suitably across at least <NUM>% of the length of the receptacle). Said length of the receptacle is preferably in the range <NUM> to <NUM>, especially in the range <NUM> to <NUM>. Said internal volume of the receptacle is preferably in the range <NUM><NUM> to <NUM><NUM>, for example in the range <NUM><NUM> to <NUM><NUM> or in the range <NUM><NUM> to <NUM><NUM>. The diameter, length and/or volume are suitably selected as described to optimise a chemical reaction for example a polymerisation process and/or curing of polymer within the receptacle as described herein and/or allow the receptacle to be manipulated and/or handled by a single human operative. It is found that if the diameter, length and/or volume are too great, there may be insufficient heat transfer during a chemical reaction for example a polymerisation. This may mean that the degree of reaction, for example, polymerisation across the diameter and/or within the volume may be unacceptably variable which may result in production of an inferior product, such as an inferior drag reducing polymer.

Preferably, other than any means by which the first end is arranged to define the closed end, the receptacle includes no seams between said first and second ends. Said receptacle is preferably formed from lay-flat tubing. It is preferably sealed at said first end as described and is divergent (e.g. by being splayed) at said second end.

The aspect ratio of the receptacle may be defined as the length of the internal volume of the receptacle divided by the diameter of the internal volume of the receptacle. Said aspect ratio may be at least <NUM>, suitably at least <NUM>, preferably at least <NUM>. Said aspect ratio may be less than <NUM>, preferably less than <NUM>, more preferably less than <NUM>. Said aspect ratio may be between <NUM> and <NUM>, more preferably between <NUM> and <NUM>.

Said housing is preferably an elongate housing which is preferably arranged to support the receptacle which is suitably arranged within the housing.

Said elongate housing preferably includes cooling means for cooling reagents and/or products (eg polymer) contained in the receptacle in use.

Said elongate housing preferably includes inerting means for introducing and/or maintaining an inert atmosphere in and/or around the receptacle.

Said elongate housing preferably comprises a first elongate tube in which said receptacle is positioned. In use (e.g. when inflated and/or when containing reagents as herein described), said receptacle preferably contacts an internal surface of the first tube. At least <NUM>%, at least <NUM>%, or at least <NUM>% of the area of an external wall area of said receptacle is preferably arranged to contact said internal surface in use. Said receptacle is preferably arranged to have a substantially circularly cross-section, for example along at least <NUM>%, at least <NUM>%, at least <NUM>% or at least <NUM>% of its length. Said receptacle may be arranged such that the area of the cross-section of the receptacle may be substantially constant, for example along at least <NUM>%, at least <NUM>%, at least <NUM>% or at least <NUM>% of its length.

Preferably, said elongate housing has a circular cross-section and said receptacle can be arranged to have a circular cross-section. The ratio of the maximum diameter of the receptacle divided by the diameter of the housing, suitably in a region wherein the housing and receptacle are opposite one another, may be at least <NUM>, preferably at least <NUM>, more preferably at least <NUM>. Said ratio may be <NUM> or less, preferably less than <NUM>, more preferably less than <NUM>. Suitably the aforementioned ratios apply along at least <NUM>% or at least <NUM>% of the length of the receptacle. Thus, in a preferred embodiment, the ratio of the maximum diameter of the receptacle (measured at any position along at least <NUM>% or at least <NUM>% of the length of the receptacle) divided by the diameter of the housing at a position opposite the position at which the diameter of the receptacle is measured, is in the range <NUM> to <NUM>, preferably in the range <NUM> to <NUM>.

Said internal surface is preferably a substantially smooth surface; and/or preferably includes a relatively low coefficient of friction to enable the receptacle to slide over the internal surface, when urged to do so. Said internal surface is preferably uninterrupted across the majority (e.g. greater than <NUM>% or greater than <NUM>%) of its area. Said internal surface is preferably cylindrical, preferably circularly cylindrical. Said internal surface preferably has a constant cross-section along substantially its entire extent.

Said first elongate tube is preferably cylindrical, for example circularly cylindrical.

Said first tube is preferably rigid and/or self-supporting. It may be made of a metal, for example steel.

Said first tube may include a port (A) through a wall thereof to allow fluid to pass into and/or out of the first tube in use. Said elongate tube may include one or a plurality of such ports.

Said elongate housing preferably comprises a second elongate tube which is suitably coaxial with said first tube and said first tube is suitably positioned within the second tube. Said first and second tubes are preferably radially spaced apart so an annular gap is defined between the first and second tubes, there suitably being spacer means to maintain the gap. Said annular gap preferably defines a fluid passage for a coolant fluid.

The annular gap preferably extends around the first elongate tube so that coolant fluid suitably contacts at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or at least <NUM>% of the surface area of said first elongate tube thereby to cool the first elongate tube (and consequently the receptacle therewithin). Especially, substantially the entirety of the surface area of first elongate tube is contacted in use by coolant fluid. Thus, the arrangement may define part of a or said cooling means for cooling reagents in the receptacle in use. The cooling means is suitably arranged to remove heat generated by the polymerisation occurring within the receptacle, due to the physical and thermal contact between the external surface of the receptacle and the internal surface of the first elongate tube.

Said second tube is preferably cylindrical, for example circularly cylindrical.

Said second tube is preferably rigid and/or self-supporting. It may be made of a metal, for example steel.

Said second tube may include one or, preferably, a plurality of ports (e.g. a port (B) and a port (C)) through a wall of the second tube to allow fluid to pass into and out of the second tube (and suitably into and/or out of said annular gap), in use.

Said second tube is preferably closed at a first end (which is suitably adjacent the first end of the receptacle) by a first end plate. The first end plate may include a port (e.g. port (D)) which extends therethrough to allow fluid to pass into and out of the first and/or second tubes. Said first end plate may include one or a plurality of such ports.

The outwardly facing surface referred to in step (iii) of the method suitably faces outwardly in a direction which is parallel to the elongate extent of the housing and/or is perpendicular to the diameter of the housing. The outwardly facing surface is suitably an end face of the housing. It is suitably an end face of the first elongate tube of the elongate housing described.

The housing may include a flange, for example an annular flange, which suitably defines the outwardly facing surface. The flange may be secured to a cylindrical wall of the housing, for example a cylindrical wall of said first elongate tube when provided. Said flange preferably includes a substantially planar face which may be extended substantially perpendicular to the diameter of the housing, for example the diameter of said first elongate tube. The main face of the flange suitably faces outwardly in a direction which is parallel to the elongate extent of the housing and/or said flange extends perpendicularly to the diameter of the housing.

In step (iii) of the method, the receptacle is suitably positioned within the housing. The second end of the receptacle (e.g. the splayed end thereof) may extend out of the housing, suitably beyond said outwardly facing surface, for example said flange. The second end may then be folded over the outwardly facing surface, for example said flange. It is preferably folded over the outwardly facing surface so that it is substantially evenly distributed over the surface, thereby minimising production of folds or other irregularities in the receptacle, suitably at least up to a position wherein the receptacle contacts (e.g. makes face-to-face contact) with the outwardly facing surface, for example said flange. Advantageously, the extent of splaying and/or increased diameter at the second end (relative to the diameter inwards of said second end) of the receptacle (eg of said mouth) is selected to minimise the production of folds or other irregularities in the receptacle as described.

In step (iv) of the method, said receptacle is preferably releasably secured in position, suitably within the housing.

Thus, the housing is preferably arranged for removal of the elongate receptacle therefrom suitably after a product, for example a polymer, has been produced therein. In a preferred embodiment where the housing includes a first tube as described, the housing and/or first tube may be arranged for the receptacle to slide out of the first tube and thereby be removed and/or disengaged therefrom.

In step (iv), said second end is suitably secured in position by securement means. Said securement means may comprise a clamp for clamping the receptacle in position. When the receptacle includes a second end (which is suitably splayed as described), the securement means may be arranged to apply a force to clamp the second end and/or regions adjacent thereto in position. Said securement means may include a second end plate which is suitably arranged to apply a clamping force.

Said second end plate may include one or a plurality of ports (e.g. ports (E) and (F)) which extend therethrough to allow fluid to pass into and/or out of the elongate housing and/or said receptacle, in use.

Preferably, said second end of said receptacle is secured in position by a surface of a securement means (for example a gasket) being urged against part of the receptacle (eg said mouth) so as to clamp the receptacle between the securement means (e.g. gasket) and said outwardly facing surface (e.g. flange) of the housing. Preferably, in step (iv), said receptacle is clamped between two opposing planar surfaces - e.g. one being defined by said outwardly facing surface and a second being defined by said securement means, for example a gasket thereof.

According to a second aspect of the invention, there is provided apparatus assembled in the method of the first aspect. The apparatus may comprise:.

The apparatus of the second aspect may include any feature of the invention and/or apparatus described in the first aspect.

Any feature of receptacle and/or housing of the second aspect may be as described for said first aspect.

The apparatus of the second aspect may be for undertaking a chemical reaction, for example a polymerisation reaction for producing a drag reducing polymer.

According to an embodiment, referred to as a third aspect, there is provided a method of preparing an elongate receptacle for use in the method and/or apparatus of the first and/or second aspects, the method comprising:.

Thus, preferably, said precursor is treated so that, adjacent the second end, the precursor diverges so that, suitably, the maximum diameter of the receptacle is situated at said second end. Thus, said receptacle formed suitably converges on moving from said second end inwards, for example towards said first end.

In step (b), said precursor of said receptacle is suitably heated to enable its shape to be changed, preferably substantially permanently and/or inelastically. Preferably, in step (b), the precursor of said receptacle (e.g. a region thereof which includes said second end) is engaged with a former, for example a shaped object, which is arranged to facilitate formation of said divergent second end of the receptacle as described. Said former may be conical or frusto-conical. Suitably, said former is positioned within the precursor of the receptacle and subjected to heat, suitably to cause substantially permanent heat deformation of said precursor of said receptacle, thereby to define the receptacle described.

Before or after step (b), the method may comprise treating the precursor of said receptacle to close a first end of the receptacle. Such treatment may comprise heating a region of the precursor of said receptacle adjacent said first end. The treatment may comprise heat sealing abutting faces of the precursor of said receptacle adjacent said first end.

According to another aspect, referred to as a fourth aspect of the invention, there is provided an elongate receptacle for containing reagents for a chemical reaction, said elongate receptacle comprising a plastic material, said receptacle being arranged to define an internal volume for containing reagents, wherein said receptacle includes a first end and a second end which are spaced apart along the elongate extent of the receptacle, wherein said receptacle defines a mouth at said second end, wherein the diameter of said mouth is greater than the diameter of a region of said receptacle inwards of said second end.

Said receptacle may have any feature of the receptacle described in any preceding aspect.

The elongate receptacle of the fourth aspect may be produced in a method as described in the third aspect.

Said receptacle may include reagents and/or products produced from reagents. In a preferred embodiment, said receptacle includes a drag reducing polymer or reagents for producing a drag reducing polymer. The weight of materials, for example, drag reducing polymer, in said receptacle may be at least <NUM>, is suitably at least <NUM>, is preferably at least <NUM>, is more preferably at least <NUM> and, especially, is at least <NUM>. The total weight may be less than <NUM>, suitably less than <NUM>, preferably less than <NUM>, more preferably less than <NUM>, especially less than <NUM>. The total weight may be between <NUM> and <NUM>, preferably between <NUM> and <NUM>.

A drag reducing polymer described in any statement herein may be any conventional or known polymeric drag reducing agent (DRA) including, but not limited to, poly(alpha-olefin), polychloroprene, vinyl acetate polymers and copolymers, poly(alkylene oxide) (PAO), and mixtures thereof and the like. In one embodiment, the monomer may be any monomer which, when polymerized, forms a polymer suitable for use as a drag reducing agent (DRA). Said at least one monomer may comprise an alpha-olefin. Preferred alpha-olefins may have a carbon chain length in the range <NUM> to <NUM> carbon atoms, preferably <NUM> to <NUM>, more preferably <NUM> to <NUM> carbon atoms. Said at least one monomer may be selected from the group comprising: <NUM>-hexene, <NUM>-heptene, <NUM>-nonene, <NUM>-octene, <NUM>-decene, <NUM>-dodecene, <NUM>-tetradecene, isobutylene; alkyl acrylates; alkylmethacrylates; styrene and alkyl styrene. Copolymers (which may include two or more dissimilar monomers) of these monomers may also make suitable drag reducing agents. Preferred monomers include alpha-olefins with a carbon chain length in the range <NUM> to <NUM>, more preferably <NUM> to <NUM> carbon atoms. Preferred monomers are selected from the group comprising: <NUM>-hexene, <NUM>-heptene, <NUM>-nonene, <NUM>-octene, <NUM>-decene, <NUM>-dodecene, <NUM>-tetradecene, isobutylene. An especially preferred monomer is <NUM>-decene.

Preferred copolymer drag reducing agents may comprise repeat units derived from <NUM>-decene, optionally (but preferably) in combination with repeat units from one or more further monomers. Such further monomers may be selected from <NUM>-hexene, <NUM>-octene and <NUM>-dodecene, for example in a molar ratio of <NUM>:<NUM> to <NUM>:<NUM>. An especially preferred copolymer drag reducing agent may be prepared from a monomer mixture comprising <NUM>-hexene and <NUM>-decene.

Any known suitable catalyst and/or co-catalyst may be used in preparing a drag reducing polymer as long as they sufficiently catalyse the reaction to a sufficient extent. Metallocenes are useful catalysts for polymerizing some monomers. In the case of alpha-olefins, polymerization may be conducted by the inclusion of a mixture of Ziegler-Natta catalyst and co-catalyst(s) into the monomer. Catalysts for the polymerization of alpha-olefins include, but are not necessarily limited to, powdered catalyst TiCl<NUM>. AA (aluminum activated titanium trichloride); co-catalyst(s), diethylaluminum chloride (DEAC), and diethylaluminum ethoxide (DEALE); TEAL (triethyl aluminum chloride), tri-methyl aluminum, tri-isobutyl aluminum, MAO (methylaluminoxane), haloalkanes (e.g. <NUM>, <NUM> -dichlorethane) and the like. Of course, it will be necessary to match the co-catalyst with the main catalyst, so that the catalytic activity of the main catalyst is triggered only by the presence of a particular co-catalyst or class thereof.

Specific embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings in which:.

In the Figures, the same or similar parts are annotated with the same reference numerals.

Referring to <FIG>, apparatus <NUM> for carrying out a polymerisation reaction to produce, for example, a DRA involving monomer(s) and catalyst comprises a rigid elongate support tube assembly <NUM> which includes a coolant containing cooling jacket <NUM>. The jacket <NUM> includes a coolant inlet <NUM> and a coolant outlet <NUM>. Within the supporting tube assembly <NUM> is arranged an inflatable plastic reaction tube <NUM> (shown in a substantially filled state in <FIG>) which abuts an internal wall <NUM> of the support tube assembly <NUM>. End fitting <NUM> at one end of support tube assembly <NUM> includes a fluid port <NUM> via which an inert gas may exit the apparatus. End fitting <NUM> at an opposite end of support tube assembly <NUM> includes fluid ports <NUM>, <NUM> in which fluids (e.g. monomer(s) and/or catalyst(s) and/or inert gas) may be introduced and/or removed from the apparatus during operation. In use of the apparatus, polymer is produced within the plastic reaction tube <NUM> while the tube <NUM> is cooled by contact with internal wall <NUM> of support assembly <NUM> which is cooled by coolant passing within cooling jacket <NUM> and while a positive pressure of inert gas is maintained around the tube <NUM>. The contents of the plastic reaction tube may be maintained under inert gas conditions, through the application of inert gas via ports <NUM> and/or <NUM> while the polymerisation process is carried out. After completion of the polymerisation, end fitting <NUM> is removed and the plastic reaction tube <NUM> containing polymer produced is withdrawn from the assembly <NUM>. The reaction tube <NUM> (i.e. the plastic material of which it consists) is disengagaed, for example peeled, from the polymer to isolate the polymer from the reaction tube. The polymer may then be comminuted and formulated for use as a drag reducing additive.

Features of the apparatus and associated processes are described in greater detail below.

<FIG> illustrate steps involved in producing the inflatable plastic reaction tube <NUM> which, in its finished state, is as represented in <FIG>.

The reaction tube <NUM> is formed from <NUM> (<NUM> gauge) lay flat, polyethylene tube <NUM> which is initially not closed at either end The tube has a length of about <NUM> plus an additional <NUM> to <NUM> (to enable it to be clamped in position as described hereinafter) and a width of about <NUM> ± <NUM> when in its flattened state shown in <FIG>.

In a first step, shown in <FIG>, one end of the tube is heat sealed as represented by number <NUM>, thereby to fully close off the end and define one closed end of a receptacle for a polymerisable mixture.

In a second step, shown in <FIG>, open end of the tube <NUM> (opposite the closed end) is stretched (as illustrated by reference numeral <NUM>) over a heated cone <NUM> thereby to splay the tube in a region thereof towards its open end. As a result, the diameter of the tube <NUM> adjacent its open end gradually increases on moving from region <NUM>, inwards of the open end, to region <NUM>, situated at said open end.

In a third step, shown in <FIG>, the cone <NUM> and tube <NUM> are disengaged thereby to leave splayed open end <NUM> which has been permanently deformed by the heat treatment using the heated cone <NUM>.

The open end is splayed as aforesaid to facilitate securement of the open end within the apparatus in such a way as to minimise air gaps between the plastic reaction tube <NUM> and associated fittings of the apparatus. If air was to become trapped within folds of the plastic reaction tube <NUM>, such air could be detrimental to the polymerisation process and/or reagents used therein. In addition, the splaying facilitates production of a fluid-tight seal between the plastic tube and fittings of the apparatus.

The apparatus <NUM> may be assembled as described with reference to <FIG>.

Referring to <FIG>, support tube assembly <NUM> includes an inner rigid tube <NUM> arranged within an outer rigid tube <NUM>. Spacers (not shown) are provided between tubes <NUM>, <NUM> to maintain spacing therebetween thereby to define a passageway <NUM> between the tubes <NUM>, <NUM> in which cooling fluid can flow. Ends of the outer rigid tube are welded to the outer surface of the inner rigid tube, to close the ends of the jacket assembly. Coolant inlet <NUM> communicates with the passageway <NUM> for passage of cooling fluid from the outside into the passageway <NUM> via the inlet <NUM> and out thereof via outlet <NUM>. The cooling fluid can flow within the passageway around substantially the entirety of tube <NUM>, before it exits the passageway via coolant outlet <NUM>. Thus, a cooled, jacketed support tube assembly is arranged around the plastic reaction tube <NUM>.

Inner tube <NUM> may suitably be made from stainless steel (e.g. SS304L) of thickness <NUM>" (<NUM>) and may have an outer diameter of <NUM>" (<NUM>). The length may be 20ft (<NUM>). An inlet <NUM> (<FIG>) is provided for introduction of gas into the inside of the inner tube <NUM> as described below.

At its left-hand end, as shown in <FIG>, the inner tube <NUM> includes a narrow annular flange <NUM> which includes a flat annular face <NUM> which faces outwardly. The flange <NUM> and face <NUM> thereof are arranged for securement of the open end of tube <NUM> in position whilst minimising folds and/or other regions which may undesirably contain air and/or oxygen as hereinafter described.

Outer tube <NUM> may suitably be made from stainless steel (e.g. SS304L) of thickness <NUM>" (<NUM>) and may have an inner diameter of <NUM> and an outer diameter of <NUM>" (<NUM>). The length may be 19ft 7½" (<NUM>).

Coolant inlet <NUM> and outlet <NUM> may be fabricated with a <NUM>" NPT Weldolet (Trade Mark). A push fit adaptor may be used to allow easy connection or removal of tubing for coolant.

End fitting <NUM> may comprise a suitable gasket and a sanitary stainless steel end plate with a single tapped thread for the port <NUM>.

At the left hand end of <FIG>, there is shown a <NUM>" (<NUM>) Viton (Trade Mark) tri-clamp gasket <NUM> and an end plate <NUM>. The end plate <NUM> incorporates inlets/outlets <NUM>, <NUM> which may be tapped into the end plate. A push fit adaptor may be provided allowing convenient connection and removal of polyethylene (PE) tubing. Inlet/outlet <NUM> incorporates a ½" NPT ball valve. As described hereinafter, during the process described inlet/outlet <NUM> is used in three different steps - (a) inflation and inert gas flushing of the reaction tube <NUM>; (b) charging of monomer/catalyst mixture; and (c) flushing with inert gas after charging with the monomer/catalyst mixture (to clear delivery lines and provide additional inertion of the apparatus contents).

Also as described hereinafter, during the process described inlet/outlet <NUM> may be used as an inert gas outlet during inflation of reaction tube <NUM>, inerting and monomer/catalyst charging; and subsequently as an inlet for inert gas (to maintain a small positive pressure inside the reaction tube <NUM> for the remainder of the bulk polymerisation process).

Although in the figures the apparatus is shown with the elongate axes of tubes <NUM>, <NUM> of the support tube assembly <NUM> horizontal, it is preferred that the tubes are raised at the left hand end of <FIG> to facilitate flow of fluids from their position of introduction and into the reaction tube <NUM> defined by tube <NUM>; and to avoid loss of monomer/catalyst via port <NUM> during charging. Typically the angle defined by tubes <NUM>, <NUM> to the horizontal is about <NUM> to <NUM>° (or the gradient is about <NUM> in <NUM>).

The reaction tube <NUM>, produced from tube <NUM> as described in <FIG>, is inserted into the inner tube <NUM> and pushed thereinto so its heat sealed end <NUM> is adjacent end fitting <NUM>. As shown in <FIG>, initially the splayed open end <NUM> protrudes from the inner tube <NUM>. Next, as shown in <FIG>, the splayed open end <NUM> is turned back over flange <NUM> produced on inner tube <NUM>. The extent of splaying of the open end <NUM> is suitably such that the open end <NUM> can be turned back over flange <NUM> without it needing to be further stretched to any extent and suitably so that minimal folds are introduced as the open end <NUM> is laid over the face <NUM> of the flange <NUM>.

Next, as represented in <FIG>, gasket <NUM> and end plate <NUM> are secured in position thereby firmly (and sealingly) clamping the open end <NUM> in position as represented in <FIG>. Note in <FIG> sanitary fitting clamps have been omitted in the interests of clarity.

Note in <FIG> sanitary fitting clamps have been omitted in the interests of clarity. It should be appreciated that gasket <NUM> makes face-to-face contact with the end of the tube and the end of the tube is clamped between the gasket and flange <NUM>. It is found that the simple arrangement described serves to minimise and/or substantially avoid folds and/or pockets being defined at the end of the tube which might otherwise contain air and/or oxygen which could be detrimental to any reaction being carried out in the tube.

As will be noted from <FIG> after insertion of tube <NUM> (and prior to inflation thereof) the tube is flaccid as represented in <FIG>.

After assembly of the apparatus as described with reference to <FIG>, the apparatus may be readied for use, as described with reference to <FIG>, by inflating the tube <NUM> and inerting any region of the apparatus which may contact monomer/catalyst subsequently introduced into the apparatus, including indirect contact occurring via gas diffusion through the tube.

Referring to <FIG>, initially the volume within the apparatus outside the tube <NUM> and within the inner tube <NUM> is inerted to a specified level (e.g. less than <NUM>% vol oxygen by introduction of inert gas (e.g. nitrogen) via port inlet <NUM> as represented by arrows in <FIG>. The inert gas exits via port <NUM>. The oxygen content of gas exiting the inner tube <NUM> may be monitored at a downstream sampling point (not shown) using standard methods.

Next, the tube <NUM> is inflated as shown in <FIG>, using an inert gas (for example nitrogen). Inert gas is passed through the tube until the inert gas exiting via port <NUM> has an oxygen content (e.g. of less than <NUM>%vol), measured at a downstream sampling point (not shown). Inflation involves introduction of the inert gas via port <NUM> into the tube <NUM>.

The gas circulates within the tube <NUM> to inflate it and exits via port <NUM>. During inflation of tube <NUM>, inert gas supply via port <NUM> is stopped. Inflation of tube <NUM> can be verified by observing gas flow from port <NUM>, resulting from displacement of a gas volume from outside tube <NUM> due to inflation of the tube <NUM>. Once inflation of the tube <NUM> has been completed as shown in <FIG>, port <NUM> is temporarily closed off, while inerting of tube <NUM> is completed, to prevent air ingress via port <NUM>. Port <NUM> is reopened prior to charging of monomer(s)/catalyst(s) to the apparatus.

As an alternative to the sequence of steps described with reference to <FIG>, the sequence of steps may be interchanged - e.g. the tube <NUM> may be inflated first and then sealed before inerting the region outside tube <NUM>. Alternatively, the steps of <FIG> could be undertaken substantially simultaneously, with a slightly higher gas pressure within tube <NUM> to keep it in an inflated condition.

After completion of step <NUM>(b), the apparatus is ready to be charged with reagents and polymerisation undertaken. Referring to <FIG>, the flow of coolant in the passageway <NUM> between tubes <NUM>, <NUM> is progressed by introducing coolant thereinto via inlet <NUM> and removing coolant therefrom via outlet <NUM>. Next, a monomer/catalyst mixture is introduced into the inflated tube <NUM> via port <NUM> thereby to fill tube <NUM>. The polymerisation reaction is then allowed to proceed for an appropriate length of time (typically about <NUM> days). During this time, coolant is flowed continuously and temperature may be monitored. For example, some apparatus may inlcude a suitably positioned thermocouple <NUM> (<FIG>). In addition, a relatively low pressure (approx. <NUM> psi) of inert gas is applied via ports <NUM> and <NUM> to ensure the tube <NUM> (and its polymerising contents) is maintained under an inert atmosphere.

The monomer(s)/catalyst(s) mixture is suitably arranged to produce an ultra-high molecular weight polymer for use in drag reduction. The polymer may suitably be a polymer and/or copolymer of alpha-olefin(s).

Using the apparatus, polymer was prepared from <NUM>-decene monomer, as described in Example <NUM>.

<NUM>-decene monomer (<NUM>) was purged with nitrogen for <NUM> minutes to remove dissolved oxygen which would otherwise be poisonous to the catalyst used. The monomer was passed through a pre-treatment column containing <NUM> of a <NUM>:<NUM> mixture of 13X and 5Å molecular sieves (which had been pre-dried under vacuum at high temperature). Post the pre-treatment column, the monomer was pumped to a <NUM> litres stirred and jacketed glass lined reactor which had previously been dried and inerted to <NUM>. 3vol% oxygen or lower.

The <NUM>-decene was cooled to <NUM> and then 25wt% diethylaluminium chloride (DEAC) (<NUM>) in heptane was transferred to a Swagelok (Trade Mark) bomb within a glove box. This was then added to the <NUM>-decene under an inert atmosphere to scavenge any residual water or protic impurities. The mixture was then stirred for <NUM>-<NUM> minutes in a <NUM> litres reactor.

Inside a glovebox, titanium trichloride aluminium activated TiCl<NUM>(AAD) (<NUM>), was dispersed with stirring into anhydrous heptane (<NUM>), anhydrous <NUM>,<NUM>-dichloroethane (<NUM>) and isobutylaluminoxane (IBAO) in heptane (<NUM> wt% aluminium content in heptane) (<NUM>) was added to the catalyst dispersion. The mixture was stirred, then transferred to a Swagelok bomb and subsequently transferred to the <NUM> litres reactor, whilst maintaining an inert atmosphere, to initiate the Ziegler Natta polymerisation.

It is found that, on mixing of monomer and catalyst, polymerisation is instantly initiated and thus proceeds rapidly. The mixture was then rapidly introduced using inert gas pressure to the inflated tube <NUM> via port <NUM> as described above with reference to <FIG>.

The reaction mixture was held within tube <NUM>, as shown in <FIG>, at a jacket temperature of <NUM>. Chilled water was flowed in passageway <NUM>. After <NUM> hours, the temperature of fluid in passageway <NUM> was increased and the reaction continued.

During the entire process, both the outside and inside of tube <NUM> were kept under approximately <NUM> psi nitrogen pressure by introducing nitrogen via ports <NUM> and <NUM> to assist in restricting oxygen ingress into the polymerising mixture.

At the end of the aforementioned <NUM> days reaction time, gasket <NUM> and end plate <NUM> were disengaged as shown in <FIG>, to provide access to the tube <NUM> which contained polymer <NUM>. End plate <NUM> may optionally also be removed to allow visual inspection of polymer in the tube <NUM>. The tube <NUM> (and polymer) were then manually withdrawn from inner tube <NUM>, as shown in <FIG>. During the withdrawal, the open end of tube <NUM> was closed by a tightly drawn cable tie <NUM> (or the like). Subsequently, the tube was fully removed to isolate the sealed tube <NUM> containing an approximately <NUM> feet (<NUM>) log of polymer <NUM> as shown in <FIG>.

The tube <NUM> (which is made from polyethylene as described) can readily be detached, for example cut and/or peeled away from the log of polymer <NUM>, to thereby produce an isolated log <NUM> of polymer, as a single piece, as shown in <FIG>. Substantially no PE residue contaminates the polymer after removal of tube <NUM> which may minimise contamination of the polymer, and in turn, may be advantageous in downstream uses thereof. Whilst not wishing to be bound by any theory, the ease with which the tube can be cut away from polymer <NUM> may be related to the fact the polymer has a higher bulk density (approximately <NUM>/cm<NUM>) than the <NUM>-decene (density <NUM>/cm<NUM>) starting material which means the polymer tends to shrink away from the wall of the receptacle as it is formed.

The log of polymer <NUM> of <FIG> may be processed, by known methods and contacted with a carrier to produce a formulation comprising a DRA.

Other procedures undertaken are described in Examples <NUM> to <NUM>. Examples <NUM> to <NUM> describe procedures for assessing characteristics of polymers produced as described herein and results of such assessments.

A disposable aluminium dish was weighed to four decimal places and the weight recorded (A). A sample of the test material (<NUM> - <NUM>) was placed in the dish and the combined weight of the dish and sample also weighed to four decimal places (B). The sample was dried in a vacuum oven (<NUM>, <NUM> Torr) for one hour, removed and reweighed. This process was repeated until constant weight (C) was achieved.

The polymer conversion percentage was calculated as follows: <MAT> where D is equivalent to the percentage purity of the commercial alpha-olefin monomer used / <NUM>. For example, D = <NUM> for commercial <NUM>-decene of purity <NUM> %.

n-Hexane (~ <NUM>) was charged to a <NUM> bottle. A piece of the test polymer was sampled directly from the polymer log, as prepared in the bulk polymerisation reaction and accurately weighed to four decimal places (<NUM> - <NUM>). The polymer was then dissolved in the n-hexane by mixing for <NUM> days under low shear conditions, to provide a solution (A).

Solution (A) was then transferred to a clean, preweighed <NUM> bottle and accurately topped up with further n-hexane to provide a final polymer concentration of <NUM> / kg (<NUM> ppm w/w). The sample was manually mixed, avoiding vigorous shaking, providing partially diluted solution (B).

An aliquot of solution (B) (<NUM>) was accurately weighed into a clean, preweighed <NUM> bottle, then accurately topped up with further n-hexane to the target sample weight (<NUM>). The sample was manually mixed as above to provide working solution (C) <NUM> / kg (<NUM> ppm w/w).

Clean, preweighed collection bottles (<NUM>) were used for collection of liquids during the test runs.

The test apparatus consisted of a <NUM> litre pressure vessel, fitted with charging inlet for solvent, bottom run off (used for cleaning purposes at the end of experiments), and a dip leg connected to a length of stainless steel tubing external to the vessel (<NUM> feet length, <NUM> OD, <NUM> wall thickness). The tubing was fitted with a control valve at the outlet. The pressure vessel was further fitted with an inert gas inlet, connected to a supply line via a precision pressure control valve. This was set at a constant pressure (<NUM> psi) for all experiments.

The vessel was charged with ~ <NUM> of either working solution (C) as prepared in Step <NUM>, or untreated n-hexane (control sample), then sealed and pressurised with inert gas (<NUM> psi) with the outlet control valve closed. This valve was then opened allowing liquid to purge the external tubing, then closed (this liquid was discarded). A preweighed collection bottle (<NUM>) was placed at the outlet, then the valve reopened for <NUM> - <NUM> seconds to allow the liquid to flow again, recording the elapsed time using a stopwatch. The remaining liquid in the vessel was then discarded, rinsing the vessel thoroughly with untreated n-hexane (for test cycles where solution (C) was used).

The percentage flow improvement (%FI) and percentage drag reduction (%DR) were calculated from the hexane blank flow rate (F0) and the treated sample (solution (C)) flow rate (Fa) as follows: <MAT><MAT> then <MAT> <MAT>.

Three separate bulk polymerisation reactions (Examples <NUM> to <NUM> respectively) were carried out using the apparatus described above, with <NUM>-decene as the monomer. The synthesis procedure was identical to that described in Example <NUM> other than modification of the charges of TiCl<NUM>(AAD), <NUM>,<NUM>-dichloroethane, isobutylaluminoxane solution and heptane diluent, to provide different levels of catalyst loading (expressed as ppm w/w of Ti relative to the monomer charge weight). After completion of the bulk polymerisation the reaction tube comprising the polymer was removed according to the procedure above, and the polymer sampled for analysis, as described in Examples <NUM> and <NUM>.

For each of the polymer products, polymer conversion percentages were determined for <NUM> samples, taken from different points within the polymer log. These points were selected to provide information on the consistency of polymerisation along both the long axis and the cross sectional diameter of the polymer log.

For each of the polymer products, percentage drag reduction (%DR) was determined as described in Example <NUM> for four samples taken from different points within the polymer log. These points were selected to provide information on the consistency of product performance characteristics along the long axis of the polymer log.

The results of these experiments are shown in Table <NUM>.

The results show that, when bulk polymerisations were carried out using the apparatus described, products with excellent performance characteristics were obtained. The data shows that polymerisation could be successfully achieved using the apparatus, across a range of catalyst concentrations typical for this application. Furthermore, for each individual experiment the data showed excellent consistency in both chemical composition and performance characteristics, throughout the polymerised reaction volume.

Three separate bulk polymerisation reactions (Examples <NUM> to <NUM> respectively) were carried out using the apparatus described above, with a monomer mixture of <NUM>-hexene and <NUM>-decene. The synthesis procedure was identical to that described in Example <NUM> (120ppm w/w of Ti relative to the monomer charge weight) other than the selection of monomers. After completion of the bulk polymerisation the reaction tube <NUM> comprising the polymer was removed according to the procedure above, and the polymer sampled for analysis, as described in Examples <NUM> and <NUM>.

Polymer conversion percentages and percentage drag reduction (%DR) measurements, from multiple points within the polymer log, were taken and reported in identical manner to Examples <NUM> to <NUM>.

The results show that, when bulk polymerisations were carried out using the apparatus described to make copolymers, products with excellent performance characteristics were also obtained. Similarly to Examples <NUM> to <NUM>, the data showed excellent consistency in both chemical composition and performance characteristics, throughout the polymerised reaction volume.

An alternative, simplified, apparatus <NUM> is shown in <FIG>. The apparatus <NUM> for undertaking a chemical reaction comprises an elongate housing <NUM> and a receptacle <NUM>. The elongate housing <NUM> includes a cooling means <NUM> and end fittings <NUM>, <NUM> which include ports via which fluids may be introduced and/or removed. In use of the apparatus <NUM>, a chemical reaction product is formed within the receptacle <NUM>. Subsequently, the receptacle <NUM> containing the chemical reaction product is withdrawn from the elongate housing <NUM>.

Although only one apparatus <NUM>, <NUM> has been described, an assembly may be provided including multiple apparatuses <NUM>, <NUM> to manufacture larger amounts of polymer. Such reactors could be filled sequentially or simultaneously, optionally through the use of a manifold system.

Claim 1:
A method of assembling apparatus for containing reagents for a chemical reaction, the method comprising:
(i) selecting an elongate receptacle comprising a plastics material, said receptacle being arranged to define an internal volume for containing reagents, wherein said receptacle includes a first end and a second end which are spaced apart along the elongate extent of the receptacle, wherein said receptacle defines a mouth at said second end, wherein the diameter of said mouth is greater than the diameter of a region of said receptacle inwards of said second end;
(ii) selecting a housing for containing the receptacle, wherein said housing includes a first end and a second end, wherein said second end of said housing includes an outwardly facing surface;
(iii) with the receptacle within the housing such that the second end of the receptacle is adjacent the second end of the housing, positioning the second end of the receptacle over the outwardly facing surface; and
(iv) securing the second end of the receptacle in position relative to the outwardly facing surface.