Patent ID: 8114353

Claim:
A polymerization system comprising: (a) a polymerization reactor; (b) continuous catalyst activator comprising a substantially horizontal fluidized bed vessel, and wherein the continuous catalyst activator further comprises: (i) a gas distributor plate extending substantially horizontal within the fluidized bed vessel being arranged to allow passage of a fluidizing gas throughout the fluidized bed vessel; (ii) an inlet for introducing a catalyst into the fluidized bed vessel; (iii) at least one zone dividing wall for dividing the fluidized bed vessel into a plurality of zones, at least one of the zone dividing walls comprising a zone opening that allows the catalyst to be introduced into a next downstream zone, the plurality of zones being located substantially horizontal in relation to one another; and (iv) each zone comprising at least one baffle, each baffle defining a stage, each zone comprising a lower boundary that comprises at least a portion of the gas distributor plate; (c) a controller programmed with an algorithm to control a polymerization reactor process variable by adjusting a continuous catalyst activator process variable; and further comprising at least one of: (d1) a filter apparatus adapted to remove catalyst particles entrained in the fluidizing gas; or (d2) a cooling system wherein an oxidizing stage cools the catalyst with a first oxidizing ambient compound and a purge stage purges the catalyst with a first inert agent.