Plant and process for forming polymers

Abstract

The present disclosure relates to a plant and process for forming a polymer. In some embodiments, the process for forming a polymer includes providing a feed having one or more olefin monomers and a solvent. The process includes introducing the feed into a reactor together with a catalyst to form a reaction mixture. The process includes removing a reactor effluent from the reactor and mixing the reactor effluent with a first concentrated polymer solution in a mixer or line to form a mixture. The process includes introducing the mixture into a heat exchanger to form a heated mixture, and introducing the heated mixture into a pressure let-down valve followed by introducing the heated mixture into a phase separator. The process includes removing a second concentrated polymer solution from the phase separator. The process includes introducing the second concentrated polymer solution into a mixer or line.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 63 / 282,424, filed November 23, 2021, the entire disclosure of which is incorporated herein by reference.

[0002] Field The present disclosure relates to plants and processes for forming polymers. [Background technology]

[0003] background A continuous solution polymerization process generally involves adding a catalyst to a mixture of monomer, comonomer, and solvent to form a reaction mixture. The reaction mixture may be backmixed to provide a homogeneous polymer. The heat of the polymerization reaction, called the exotherm, may be absorbed by the reaction mixture. Alternatively, or in addition, the heat of reaction may be removed by a cooling system, for example, by external cooling of the reactor vessel walls or by internally located heat exchange surfaces cooled by a heat exchange fluid. During the polymerization, most of the monomer is consumed, and the polymer formed remains dissolved in the solvent used during polymerization. Typically, the higher the polymer concentration, the higher the viscosity of the polymerization reaction mixture containing the polymer, solvent, and unreacted components. After polymerization, the reaction mixture moves from the polymerization reactor to a finishing section, where the polymer, solvent, and unreacted monomer are separated (e.g., by devolatilization). In this finishing process, the solvent and unreacted monomer are gradually removed from the reaction mixture until the polymer can be formed into solid pellets or bales. The separated solvent and monomer can be recycled to the polymerization reactor. Polymer devolatilization is a technique for improving polymer quality and is used in the industrial production of adhesives, elastomers, surface coatings, and plastic materials (e.g., thermosets and thermoplastics). Devolatilization processes can remove volatile components, such as monomers, oligomers, additives, and solvents involved in polymerization, as well as by-products, from polymers. Devolatilization processes can remove residual volatile organic compounds (VOCs) from polymers, facilitating compliance with government regulations.

[0004] One method for separating polymers from volatile organic compounds is by evaporation, in which the polymer solution is heated above the vaporization temperature of the volatile components. The equipment and methods utilized often depend on the viscosity of the polymer solution, and these devices often have high initial and operating costs. To achieve high polymer production, oversized equipment and high mechanical energy consumption are typically required. Furthermore, these devices subject the polymer to high temperatures and mechanical shear, which can potentially cause degradation of the polymer's physical properties. Furthermore, techniques that heat the polymer solution in a heat exchange zone involve exposing the polymer solution to high temperatures for extended periods of time. Such heat exposure can cause thermal degradation of the heat-sensitive polymer, resulting in discoloration of the polymer and / or loss of properties such as impact strength. Furthermore, techniques that avoid degradation of heat-sensitive polymers can result in low production yields. For example, polymers typically experience mild temperatures and long residence times in the devolatilizer. When this occurs, production is compromised due to low flow rates through the devolatilizer.

[0005] When effluent is removed from a polymerization reactor, heat may be introduced to the effluent from the polymerization reactor via a heat exchanger before the reactor effluent is introduced into a devolatilization vessel. However, such a heat exchanger must provide substantial heat for the subsequent devolatilization to occur in the devolatilization vessel, which promotes polymer decomposition and fouling within the lines carrying the reactor effluent and the devolatilization vessel. Alternatively, concentrated polymer removed from the devolatilization vessel may be recycled directly to the devolatilization vessel via a line connected to the heat exchanger. This heat exchanger must provide substantial heat for the devolatilization to occur, which results in polymer decomposition and fouling within the recycle lines and the devolatilization vessel. Furthermore, such heat exchangers must operate at high temperatures while maintaining high pressures to prevent undesirable phase separation of the polymer and volatile material mixture within the heat exchanger.

[0006] Furthermore, the presence of the recycle line (and the presence of recycled concentrated polymer in the devolatilization vessel due to the polymer recycle) significantly increases the residence time of the devolatilization process compared to a devolatilization process using a vessel without a recycle line. This residence time can be even longer if the size of the recycle heat exchanger must be large due to the large amount of heat required (provided by the recycled concentrated polymer). For example, a recycle of 725,000 lb / hr or more of recycled concentrated polymer from the devolatilization vessel is typically provided (via a line) to a heat exchanger (operating at a heat addition of 55 MMBtu / hr or more to the recycle stream) before the heated recycled polymer is directly reintroduced into the devolatilization vessel. Such additional heating not only accelerates polymer degradation, but in plants producing multiple different grades of polymer, it also makes the transition time between producing different polymer grades very long and expensive (due to the large amount of polymer present in the recycle line when it is shut down to transition to a different polymer grade). For example, there is a need for devolatilization plants and processes that allow for short transition times between polymer grades in a manner that also reduces the amount of off-spec material produced (e.g., cracked polymer and less recycled concentrated polymer in the recycle line). Summary of the Invention

[0007] overview In some embodiments, a process for forming a polymer includes providing a feed having one or more olefin monomers and a solvent. The process includes introducing the feed into a reactor together with a catalyst to form a reaction mixture. The process includes removing a reactor effluent from the reactor and mixing the reactor effluent with a first concentrated polymer solution in a mixer or line to form a mixture. The process includes introducing the mixture into a heat exchanger to form a heated mixture, and introducing the heated mixture into a pressure let-down valve before introducing the heated mixture into a phase separator. The process includes removing a second concentrated polymer solution from the phase separator. The process includes introducing the second concentrated polymer solution into the mixer or line. In some embodiments, a plant for forming a polymer includes a polymerization reactor coupled to a phase separator. The plant includes a heat exchanger and a pressure letdown valve disposed between the polymerization reactor and the phase separator. The heat exchanger is coupled to the polymerization reactor and the pressure letdown valve. The pressure letdown valve is coupled to the phase separator. The plant includes a stream stripper coupled to the phase separator and in line at a location upstream of the heat exchanger and the pressure letdown valve. These and other features and characteristics of the viscosity modifiers of the present disclosure and their advantageous applications and / or uses will be apparent from the detailed description below.

[0008] So that the above-mentioned features of the present disclosure can be understood in detail, a more particular description of the disclosure briefly summarized above will be found by reference to embodiments, some of which are illustrated in the accompanying drawings. However, the accompanying drawings illustrate only exemplary embodiments of the present disclosure and should not be considered as limiting the scope of the present disclosure, since the present disclosure may admit of other equally effective embodiments. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a schematic layout of a plant and process flow for polymerization and devolatilization according to an embodiment. [Figure 2] 2 is a schematic layout of a portion of the plant and process flow of FIG. 1 (during normal operating mode) according to an embodiment. [Figure 3A] 1 illustrates a phase separator of a plant and process flow according to an embodiment. [Figure 3B] 1 illustrates a phase separator of a plant and process flow according to an embodiment. [Figure 4] 1 is a heat exchanger according to an embodiment. [Figure 5] 1 is a plate heat exchanger according to an embodiment. [Figure 6] 1 is a plate heat exchanger according to an embodiment. [Figure 7] 1 is a plate heat exchanger according to an embodiment.

[0010] For ease of understanding, the same reference numerals have been used, where possible, to designate identical elements common to the figures. The figures may not be to scale and may be simplified for clarity. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further description. DETAILED DESCRIPTION OF THE INVENTION

[0011] Detailed Description The present disclosure relates to plants and processes for forming polymers. In some embodiments, a process for forming a polymer includes providing a feed having one or more olefin monomers and a solvent. The process includes introducing the feed into a reactor together with a catalyst to form a reaction mixture and removing a reactor effluent from the reactor. The process includes mixing the reactor effluent with a first concentrated polymer solution in a mixer or line to form a mixture. The process includes introducing the mixture into a heat exchanger to form a heated mixture. The process includes introducing the heated mixture into a pressure letdown valve followed by introducing the heated mixture into a phase separator. The process includes removing a second concentrated polymer solution from the phase separator. The process includes introducing the second concentrated polymer solution into the mixer or line.

[0012] In some embodiments, a plant for forming a polymer includes a polymerization reactor coupled to a phase separator. The plant includes a heat exchanger and a pressure letdown valve disposed between the polymerization reactor and the phase separator. The heat exchanger is coupled to the polymerization reactor and the pressure letdown valve, and the pressure letdown valve is coupled to the phase separator. The plant includes a stream stripper coupled to the phase separator and in line at a location upstream of the heat exchanger and the pressure letdown valve.

[0013] The disclosed plant and process provides a reactor effluent mixed with a concentrated polymer solution recycle stream (from a phase separator, also called a devolatilizer). This mixture may pass through a heat exchanger before entering the phase separator. Heat exchange may also be achieved using a heat exchanger disposed within the phase separator. Because heat exchange is provided to the mixture in two or more locations, each of the two or more heat exchange processes (in the two or more heat exchangers) can be performed at a lower temperature than in a conventional single heat exchanger, resulting in a reduction in the amount of off-specification (e.g., degraded polymer) in the polymer product produced. Otherwise, the addition of all the heat in the first heat exchanger would significantly increase the heat exchanger outlet temperature, leading to undesirable phase separation of the effluent. Furthermore, providing a large amount of heat to the phase separator itself would require an oversized vessel.

[0014] Furthermore, the heat exchanger disposed within the devolatilization vessel of the present disclosure provides heat to the concentrated polymer solution exiting the phase separator, which, in addition to mixing the concentrated polymer solution with the reactor effluent prior to the first heat exchange, results in a reduction in the amount of heat available for the first heat exchange (further reducing polymer degradation). Because the first heat exchange (between the reactor effluent and the recycled concentrated polymer solution) does not require as much heat, a smaller amount of recycled concentrated polymer solution can be used during the normal operating mode of the plant. Because a smaller amount of recycled concentrated polymer solution can be used during the normal operating mode, this results in a reduction in the amount of off-specification material produced (e.g., decomposed polymer and less recycled concentrated polymer solution in the recycle line), as well as a shorter transition time between polymer grades. For example, in some embodiments, the plants and / or processes of the present disclosure employ an hourly recycle of up to 500,000 lb / hr, e.g., up to 400,000 lb / hr, e.g., from about 100,000 lb / hr to about 400,000 lb / hr, e.g., from about 200,000 lb / hr to about 300,000 lb / hr, of concentrated polymer recycled from devolatilization.

[0015] Additionally, the presence of recycled concentrated polymer solution in the first heat exchanger reduces or eliminates phase separation (liquid-liquid or gas-liquid) of the mixture inside the heat exchanger, which would otherwise cause heat transfer and operational problems. For the transition mode, the plants and processes of the present disclosure allow for the recycle stream of concentrated polymer solution to be closed off so that significant amounts of off-specification material (e.g., concentrated polymer stagnation inside the recycle line and heat exchangers therein) do not occur during grade transition. In other words, the devolatilization can have a reduced devolatilization residence time, for example, a devolatilization residence time that is reduced by one-third or more compared to conventional devolatilization processes. Additionally, the heat exchangers of the present disclosure (e.g., disposed within the devolatilization vessel) can have a tube-and-tube design in which tubes are grouped together in bundles, e.g., 8000 m 2 Compared to conventional tube bundles, the heat exchanger of the present disclosure can provide a significant distribution of the reactor effluent (or a mixture of the reactor effluent and concentrated polymer solution) and increase the gas-liquid interface of the reactor effluent (or a mixture of the reactor effluent and concentrated polymer solution).

[0016] Polymerization conditions In some embodiments, a process for forming a polymer is provided, the process comprising: (a) providing a feed having one or more monomers and a solvent; (b) introducing the feed into a reactor along with a catalyst; and (c) removing a reactor effluent from the reactor for further processing. In one or more embodiments, the reactor can be a single reactor or multiple reactors, for example, two reactors arranged in parallel or series. One or more of the reactors can be a loop reactor. Additionally or alternatively, the reactor is a continuous stirred tank reactor. In one or more embodiments, two reactors are arranged in parallel or series, and the ratio of the internal volume of the first reactor to the internal volume of the second reactor can have a minimum ratio value of 50:50, 55:45, 60:40, 65:35, 70:30, 80:10, 85:15, or 90:10, and a maximum ratio value of 55:45, 60:40, 65:35, 70:30, 80:20, 85:15, 90:10, or 95:5, as long as the maximum ratio value is greater than the minimum ratio value. The reaction mixture from the two reactors is combined and then sent to a phase separator.

[0017] The monomers and catalyst may be supplied to the reactor by any suitable unit or apparatus. The plant may include a feed supply unit for supplying a feed having one or more olefin monomers in a solvent, such as a hydrocarbon solvent. The plant of the present disclosure may also include a catalyst supply unit suitable for supplying a catalyst to the reactor. A feed supply unit suitable for supplying a feed of one or more olein monomers in a solvent to the reactor may be any suitable apparatus, but will typically include a feed conduit for each monomer, a feed conduit for a recycled solvent, and a feed conduit for an unused solvent. Each of these conduits may be fed to a common feed conduit prior to entry into the reactor. One or more pumps may be used to supply the feed to one or more reactors and pressurize the feed to the desired pressure. A catalyst supply unit suitable for supplying a catalyst to the reactor may be any suitable apparatus, but will typically include a feed conduit for the catalyst and, optionally, one or more pumps for pumping the catalyst to one or more reactors.

[0018] The solvent used for the polymerization can be any suitable solvent, such as hexane and / or isohexane. For example, the solvent is a non-polar solvent that does not coordinate with or interact with the catalyst, in the sense that it does not inhibit the catalytic action of the catalyst system. The process of the present application can use low-boiling alkane solvents, or mixtures thereof, which can be linear or branched, for example, having 4 to 10 carbon atoms, preferably 5 to 7 carbon atoms, optionally in mixtures with other alkanes of higher or lower molecular weight. The polymers can be derived from monomers containing monoolefins such as ethylene or propylene or other higher alpha olefins having 4 to 10 carbon atoms. This combination provides a mixture that can be easily separated in a liquid phase separator.

[0019] The operating pressure of the reactors described herein can be 8 MPa or more, 9 MPa or more; 10 MPa or more, 12 MPa or more, or 14 MPa or more. The upper pressure limit is not strictly limited, but can typically be 20 MPa or less, e.g., 18 MPa or less, or 15 MPa or less, or 14 MPa or less, or 12 MPa or less. In some embodiments, the pressure is sufficient to keep the reaction mixture in a single phase and provide a working pressure to transport the fluid through the plant. The feed temperature can vary depending on the available exotherm and the degree of monomer conversion desired to reach the polymerization temperature. In some embodiments, the temperature is 40°C or less, or 20°C or less, or 0°C or less, or -20°C or less. The polymerization temperature can vary depending on the desired molecular weight of the polymer, allowing for the influence of any chain transfer agents, such as added hydrogen. In a series reactor process, the temperature within the series of reactors can be gradually increased in increments depending on the nature of the polymerization occurring within the reactors. In some embodiments, the polymerization temperature for polymers containing primarily (e.g., 50 wt% or more) ethylene-derived units is at least 100°C, or at least 150°C, or 200°C or more, depending on the particular polymer being synthesized. The temperature should not exceed the polymerization decomposition temperature or the temperature at which the catalyst can sustain the polymerization reaction.

[0020] Overall, the exotherm can result in a temperature difference between the inlet and outlet temperatures of the polymerization reactor of from 50° C. to 220° C. or even 250° C. In one or more embodiments, feeding the feed at minus 40° C. and allowing the exotherm to raise the temperature to 210° C. can result in the process producing lower molecular weight polymers. For higher molecular weight polymers, it may be necessary to limit the temperature increase with warmer feeds and / or lower reactor temperatures to avoid excessive viscosity of the reactor solution, which would degrade the mixing performance of the reactor and thereby result in a non-uniform polymer. The monomer concentration can depend on the type and molecular weight of the target polymer, the relative conversion of monomer to polymer, and the operating temperature. For example, the monomer concentration can be greater than 10 wt. %, or 15 wt. %, and less than 80 wt. %, 70 wt. %, or 60 wt. The total vapor pressure of all components can be less than 100 wt. % of the reactor pressure at the stream temperature to avoid the formation of vapor bubbles.

[0021] The polymerization can be carried out using any suitable catalyst, such as a Ziegler-Natta catalyst, a single-site catalyst (SSC), or a metallocene catalyst. In one or more embodiments, an SSC or metallocene catalyst can be used. The term "metallocene" refers to one or more cyclopentadienyl moieties combined with a transition metal of the periodic table of elements. As used herein, the numbering conventions of the periodic table of elements are used as described in CHEMICAL AND ENGINEERING NEWS, 63(5), 27 (1985). Metallocene catalysts generally contain a transition metal from Groups 3-10 of the periodic table and at least one ancillary ligand that remains bound to the transition metal during polymerization. In some embodiments, the transition metal is used in its cationic state and stabilized by a cocatalyst or activator. In some embodiments, a metallocene from Group 4 of the periodic table, such as titanium, hafnium, or zirconium, is used in the polymerization in its monovalent cationic state and with one or two ancillary ligands.

[0022] In some embodiments, the catalyst is a bulky ligand transition metal catalyst. The "bulky ligand" contains a variety of bonding atoms, such as carbon atoms, forming a group that may be cyclic with one or more heteroatoms. The bulky ligand may be a metallocene-type cyclopentadienyl derivative, which may be mononuclear or polynuclear. One or more bulky ligands may be bonded to the transition metal atom. Other ligands may be, for example, hydrocarbyl or halogen leaving groups, bonded or coordinated to the transition metal and removable, for example, by a cocatalyst or activator. Removal of any such ligand results in the creation of a coordination site at which an olefin monomer can be inserted into the polymer chain. In some embodiments, the transition metal atom is a Group 4, 5, or 6 transition metal, such as a Group 4 atom, of the periodic table of elements.

[0023] Metallocene catalysts can be used with a cocatalyst, such as an alumoxane, such as methylalumoxane, having an average degree of oligomerization of 4 to 30, as determined by vapor pressure osmometry. Alumoxanes can be modified to provide solubility for linear alkanes or used in slurries, but are typically used from a toluene solution. The solution may contain unreacted trialkylammonium, and the alumoxane concentration can typically be expressed as moles of Al per liter, including any trialkylaluminum that has not reacted to form oligomers. When used as a cocatalyst, alumoxanes are typically used in molar excess relative to the transition metal, such as at a molar ratio of 50 or greater, e.g., 100 or greater, to 1000 or less, e.g., 500 or less. The SSC can be selected from a wide range of available SSCs to tailor the type of polymer made and its associated process window so that under process conditions an activity of at least 40,000 g, e.g., at least 60,000 g, or even more than 100,000 g of polymer per gram of SSC (or metallocene) can be produced. By being able to produce a variety of polymers in different operating windows in conjunction with the selection of the appropriate catalyst, the SSC and auxiliary catalyst components can be used in smaller amounts, and in some cases, small amounts of scavengers can be used.

[0024] The metallocene may be used with a cocatalyst, which may be a non-coordinating anion (as used herein, the term "non-coordinating anion" encompasses weakly coordinating anions, the coordination of which may be sufficiently weak to permit insertion of the unsaturated monomer component in any event evident from the progress of the polymerization). The non-coordinating anion may be provided and reacted with the metallocene in any suitable manner. A precursor of a non-coordinating anion may be used with the metallocene provided in a reduced valence state. This precursor may undergo a redox reaction. The precursor may be an ion pair, and the precursor cation may be neutralized and / or removed in some way. The non-coordinating anion can be a halogenated, tetraaryl-substituted, non-carbon-based anion of Groups 10-14, particularly one having a fluorine group replacing a hydrogen atom on an aryl group or an alkyl substituent on the aryl group.

[0025] In some embodiments, effective Group 10-14 cocatalyst complexes derived from ionic salts include tetracoordinate Group 10-14 anion complexes, where the anion can be represented by the formula: [(M)Q 1 Q 2 ...Q i ] - wherein M is one or more Group 10-14 metalloids or metals, preferably boron or aluminum, and each Q is a suitable non-coordinating anion [(M)Q 1 Q2 ...Q i ] - or a sufficient number of Q's are effective ligands to provide an electronic or static effect that gives 1 Q 2 ...Q i ] - is an effective non-coordinating or weakly coordinating anion. Exemplary Q substituents include, in particular, fluorinated aryl groups, preferably perfluoroaryl groups, and substituted Q groups having substituents in addition to fluorine substitution, such as fluorinated hydrocarbyl groups. Preferred fluorinated aryl groups include phenyl, biphenyl, naphthyl, and derivatives thereof. The non-coordinating anion may be used in approximately equimolar amounts relative to the transition metal component, for example at least 0.25, preferably 0.5, especially 0.8, and up to, for example, 4, preferably 2, especially 1.5.

[0026] Representative metallocene compounds may have the formula: L A L B L C i MDE In the formula, L A is a substituted cyclopentadienyl or heterocyclopentadienyl ancillary ligand π-bonded to M; L B L A or J, a heteroatom ancillary ligand σ-bonded to M; L A Ligand and L B The ligands may be covalently linked together via a Group 14 element linking group; C i is an optional neutral non-oxidizing ligand having a coordinate bond to M (i equals 0 to 3); M is a Group 4 or 5 transition metal; and D and E independently each have a σ bond to M and are optionally connected to each other or to L. A Or L BThe monoanionic ligand is a labile monoanionic ligand bridged by a transition metal component, which can be displaced by a suitable activator to allow insertion of a polymerizable monomer or macromonomer for coordination polymerization onto the vacant coordination site of the transition metal component.

[0027] Representative nonmetallocene transition metal compounds that can be used as the SSC also include tetrabenzylzirconium, tetrabis(trimethylsilylmethyl)zirconium, oxotris(trimethylsilylmethyl)vanadium, tetrabenzylhafnium, tetrabenzyltitanium, bis(hexamethyldisilazide)dimethyltitanium, tris(trimethylsilylmethyl)niobium dichloride, and tris(trimethylsilylmethyl)tantalum dichloride. Additional organometallic transition metal compounds suitable as olefin polymerization catalysts according to embodiments described herein will be any Group 3-10 compound that can be converted to a catalytically active cation by ligand abstraction and stabilized by a non-coordinating or weakly coordinating anion that is sufficiently labile to be displaced in its active electronic state by an olefinically unsaturated monomer such as ethylene. For example, metallocenes that are biscyclopentadienyl derivatives of Group 4 transition metals, preferably zirconium or hafnium, can be used, as disclosed in WO 99 / 41294. These can be derivatives containing fluorenyl and cyclopentadienyl ligands, advantageously linked by a single carbon and silicon atom, as disclosed in WO 99 / 45040 and WO 99 / 45041. In some embodiments, the Cp ring is unsubstituted and / or the bridge contains alkyl, preferably alkylsilyl, substituents to aid in the alkane solubility of the metallocene, as disclosed in WO 00 / 24792 and WO 00 / 24793. Other possible metallocenes include those described in WO 01 / 58912.

[0028] WO 97 / 03992, incorporated herein by reference, shows catalysts in which a single Cp species and phenol are linked by a C or Si bond, such as MeC(Cp)(3-tBu-5-Me-2-phenoxy)TiCl. WO 2001 / 05849, incorporated herein by reference, discloses Cp-phosphinimine catalysts, such as (Cp)((tBu)P=N-)TiCl. Other suitable metallocenes may be, for example, bisfluorenyl derivatives or unbridged indenyl derivatives which may be substituted at one or more positions of the fused ring with moieties which have the effect of increasing the molecular weight and indirectly allow polymerization at higher temperatures, as described in EP 0 693 506 and EP 0 780 395. When using the above catalysts, the overall catalyst system typically further comprises one or more organometallic compounds as scavengers. These scavengers include compounds effective for removing polar impurities from the reaction environment and for enhancing catalyst activity. Impurities, which may be inadvertently introduced with any of the polymerization reaction components, particularly with the solvent, monomer, and catalyst feed, can adversely affect catalyst activity and stability, reducing or even eliminating catalyst activity, particularly when ionizable anion precursors activate the catalyst system. Impurities or catalyst poisons include water, oxygen, polar organic compounds, metal impurities, and the like. While some embodiments incorporate steps to remove these poisons prior to their introduction into the reaction vessel, for example, by chemical treatment or careful separation techniques after or during the synthesis or preparation of the various components, some small amount of organometallic compound will still typically be used in the polymerization process itself.

[0029] The scavenger can be an organometallic compound, such as the Group 13 organometallic compounds described in U.S. Patents 5,153,157 and 5,241,025, International Publication Nos. WO 91 / 09882, WO 94 / 03506, WO 93 / 14132, and WO 95 / 07941. Exemplary compounds include triethylaluminum, triethylborane, triisobutylaluminum, tri-n-octylaluminum, methylalumoxane, and isobutylalumoxane. Alumoxanes may also be used in scavenging amounts in conjunction with other means of activation, such as methylalumoxane and triisobutylalumoxane with boron-based activators. Since excessive amounts can act as catalyst poisons, the amount of scavenger used with the catalyst compound during the polymerization reaction can be minimized to an amount effective to enhance activity (or, if used in a dual role, to an amount necessary to activate the catalyst compound).

[0030] Polymerizations that yield a wide variety of polymer types and molecular weights are achievable. Generally speaking, polymers are derived from either ethylene or propylene as the primary (e.g., greater than 50 wt%) component. The polymers may contain preferably 5 mol % to 40 mol % comonomers to modify crystallinity and flexibility. The comonomers may be alpha-olefins (including cyclic olefins, such as styrene) having 2 to 20 carbon atoms, such as ethylene (for polymers primarily composed of propylene-derived units), propylene, 1-butene, 1-hexene, and 1-octene. Amounts of dienes, such as hexadiene, vinylnorbornene, ethylidenenorbornene (ENB), norbornadiene, etc., may be included to promote the formation of longer branches resulting from unsaturation and / or polymerized monomer-derived units.

[0031] In the case of plastomers, the polymers that can be produced may include the following: the comonomer is an alpha-olefin having 3 to 15 carbon atoms, e.g., 4 to 12 carbon atoms, e.g., 4 to 10 carbon atoms. Ethylene may be polymerized with at least two comonomers to form a terpolymer. Ethylene may be polymerized in a ratio of 70 mol% to 99.99 mol%, e.g., 70 mol% to 97 mol%, e.g., 80 mol% to 95 mol% ethylene to 0.01 mol% to 30 mol%, e.g., 3 mol% to 30 mol%, e.g., 5 mol% to 20 mol% comonomer. The molecular weight distribution of the polymer can be determined using a Waters gel permeation chromatograph equipped with an Ultra Stillagel column and a refractive index detector. The operating temperature of the instrument can be set to 145°C, the elution solvent can be trichlorobenzene, and calibration standards can include 16 polystyrenes of precisely known molecular weight ranging from 500 to 5.2 million, and a polyethylene standard, NBS 1475.10. The molecular weight distribution of the plastomer produced may have a narrow molecular weight distribution, i.e., Mw / Mn may be 3 or less, such as 2.5 or less. The MI of the polymer may be 0.01 dg / min to 200 dg / min, such as 0.1 dg / min to 100 dg / min, such as 0.2 dg / min to 50 dg / min, for example less than 10 dg / min. The plastomer may have a molecular weight of 0.85 g / cm 3 ~0.93g / cm 3 , e.g., 0.87 g / cm 3 ~0.92g / cm 3 , e.g., 0.88 g / cm 3 ~0.91g / cm 3 The density may be

[0032] The processes described herein may involve copolymerization reactions involving the polymerization of one or more alpha-olefin monomers, such as ethylene, propylene, 1-butene, 1-pentene, 1,4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, and cyclic olefins, such as styrene. Other monomers include polar vinyl, diene, norbornene, acetylene, and aldehyde monomers. In the case of elastomers, polymers that can be produced include ethylene-alpha olefin-diene elastomers (EODEs) with high Mw and diene content greater than 0.3 wt%, e.g., greater than 2 wt%. These polymers can be largely amorphous and have low or no heat of fusion. As used herein, the term "EODE" encompasses elastomeric polymers that include ethylene, an alpha olefin, and one or more non-conjugated diene monomers. The non-conjugated diene monomers can be linear, branched, or cyclic hydrocarbon dienes having 6 to 15 carbon atoms. Examples of suitable non-conjugated dienes include straight-chain acyclic dienes such as 1,4-hexadiene and 1,6-octadiene; branched-chain acyclic dienes such as 5-methyl-1,4-hexadiene; 3,7-dimethyl-1,6-octadiene; 3,7-dimethyl-1,7-octadiene and mixed isomers of dihydromyricene and dihydroocinene; monocyclic alicyclic dienes such as 1,4-cyclohexadiene and 1,5-cyclododecadiene; and polycyclic fused-ring and bridged-ring dienes such as tetrahydroindene. bicyclo-1,5-(2,2,1)-hepta-2,5-diene; alkenyl, alkylidene, cycloalkylidene norbornenes such as 5-methylene-2-norbornene (MNB); 5-propenyl-2-norbornene, 5-isopropylidene-2-norbornene, 5-(4-cyclopentenyl)-2-norbornene, 5-cyclohexylidene-2-norbornene, 5-vinyl-2-norbornene, and norbornadiene.

[0033] Suitable dienes for use in preparing ethylene-propylene-diene elastomers (EPDM) can be 1,4-hexadiene (HD), 5-ethylidene-2-norbornene (ENB), 5-vinylidene-2-norbornene (VNB), 5-methylene-2-norbornene (MNB), and dicyclopentadiene (DCPD). In at least one embodiment, the dienes are 5-ethylidene-2-norbornene (ENB) and 1,4-hexadiene (HD), for example, the EOD elastomer can contain from 20 wt% to 90 wt% ethylene, for example, 30 wt% to 85 wt% ethylene, for example, 35 wt% to 80 wt% ethylene, based on the weight of the EOD elastomer. Suitable alpha-olefins for use in preparing elastomers with ethylene and dienes can be propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, and 1-dodecene. In at least one embodiment, the alpha-olefin is incorporated into the EODE polymer at 10 wt% to 80 wt%, e.g., 20 wt% to 65 wt%, based on the weight of the EODE polymer. Non-conjugated dienes are typically incorporated into the EODE polymer at 0.5 wt% to 20 wt%, e.g., 1 wt% to 15 wt%, e.g., 2 wt% to 12 wt%, based on the weight of the EODE polymer. If desired, multiple dienes, such as HD and ENB, can be incorporated simultaneously, with the total diene incorporation within the above-mentioned limits. In at least one embodiment of the present disclosure, the elastomer can be a low-viscosity polymer, such as low-viscosity Vistamaxx™ (LVV).

[0034] In at least one embodiment, a suitable elastomer may be a copolymer of two monomers. The copolymer may be a relatively high Mw, low crystallinity, and low ash elastomer. The copolymer may be a high Mw ethylene-alpha olefin copolymer. The ethylene-alpha olefin copolymer may be a copolymer of ethylene and an alpha olefin, not necessarily propylene, that exhibits elastomeric properties. Alpha olefins suitable for use in preparing ethylene-containing elastomers include C3-C 10The α-olefin may be an α-olefin. Illustrative non-limiting examples of the α-olefin are propylene, 1-butene, 1-pentene, 1-hexene, 1-octene, and 1-dodecene. In at least one embodiment, multiple α-olefins may be incorporated. The ethylene-α-olefin copolymer may contain 20 wt% to 90 wt% ethylene, for example, 30 wt% to 85 wt% ethylene, for example, 35 wt% to 80 wt% ethylene. In at least one embodiment, the elastomer can be a propylene-based polymer having predominantly (greater than or equal to 50 wt%) propylene-derived units.

[0035] In at least one embodiment, the propylene-based polymer may be composed of propylene, at least one comonomer, and optionally a diene. The comonomer may be ethylene or an alpha-olefin. The comonomers include ethylene and linear or branched C4-C6 olefins. 30Suitable linear alpha olefins include ethylene and C4-C8 alpha olefins, such as ethylene, 1-butene, 1-hexene, and 1-octene, such as ethylene or 1-butene. Suitable branched alpha olefins include 4-methyl-1-pentene, 3-methyl-1-pentene, and 3,5,5-trimethyl-1-hexene. In at least one embodiment, the propylene copolymer may be a random copolymer, as that term is defined herein below. Dienes may also be included in the propylene-based polymer. In at least one embodiment, dienes include straight-chain acyclic dienes such as 1,4-hexadiene and 1,6-octadiene; branched-chain acyclic dienes such as 5-methyl-1,4-hexadiene; 3,7-dimethyl-1,6-octadiene; 3,7-dimethyl-1,7-octadiene and mixed isomers of dihydromyricene and dihydroocinene; monocyclic alicyclic dienes such as 1,4-cyclohexadiene and 1,5-cyclododecadiene; and polycyclic fused-ring and bridged-ring dienes such as tetrahydroindene, methyl ... non-conjugated dienes include methyltetrahydroindene, dicyclopentadiene; bicyclo-1,5-(2,2,1)-hepta-2,5-diene; alkenyl, alkylidene, cycloalkylidene norbornenes such as 5-methylene-2-norbornene (MNB); 5-propenyl-2-norbornene, 5-isopropylidene-2-norbornene, 5-(4-cyclopentenyl)-2-norbornene, 5-cyclohexylidene-2-norbornene, 5-vinyl-2-norbornene, and norbornadiene. Propylene-based polymers can include 1,4-hexadiene (HD), 5-ethylidene-2-norbornene (ENB), 5-vinylidene-2-norbornene (VNB), 5-methylene-2-norbornene (MNB), and dicyclopentadiene (DCPD).

[0036] In at least one embodiment, the propylene-based polymer can have a crystallinity of 2% to 65%. Within this crystallinity range, alternative limits of crystallinity can be from about 5% to about 50%, e.g., from about 10% to about 45%, e.g., from about 15% to about 40%. The crystallinity of the propylene-based polymer is derived from isotactic (or alternatively, syndiotactic) polypropylene sequences in the copolymer. In at least one embodiment, the amount of propylene can be from 65% to 95% by weight, e.g., from about 70% to 92%, e.g., from about 80% to 89% by weight. In at least one embodiment, the propylene-based polymer has a single broad melting transition. Samples of the propylene-based polymer may exhibit secondary melting peaks or shoulders adjacent to the main peak, and this combination is collectively considered a single melting point, i.e., a single broad melting transition. The height of these peaks is considered the melting point. In at least one embodiment, the propylene-based polymer has a melting point between 25°C and 110°C, e.g., between 30°C and 105°C, e.g., between 35°C and 90°C.

[0037] The propylene-based polymer may be a crystallizable random copolymer having a narrow composition distribution. The intermolecular composition distribution of the polymer is determined by thermal fractionation in a solvent. A suitable solvent may be a saturated hydrocarbon, such as isohexane or hexane. The thermal fractionation procedure is described below. In at least one embodiment, about 75 wt% or more, e.g., about 85 wt%, of the polymer is separated into one or two adjacent soluble fractions, with the remainder of the polymer falling into the immediately preceding or subsequent fraction. Each of these fractions has a composition (wt% ethylene content) that differs by no more than 20% (relative), e.g., no more than 10% (relative), from the average wt% ethylene content of the propylene-based polymer. For purposes of this disclosure, a propylene-based polymer may be considered to have a "narrow" composition distribution if it passes the fractionation test described above. The length and distribution of stereoregular propylene sequences in suitable propylene-based polymers can be consistent with substantially random statistical copolymerization. Without being bound by theory, the length and distribution of sequences are related to the reactivity ratio of copolymerization. As used herein, the term "substantially random" refers to a copolymer in which the product of reactivity ratios is about 2 or less. In contrast, in a stereoblock structure, the length of PP sequences is longer than that of a substantially random copolymer with a similar composition. The reactivity ratio and sequence distribution of the polymer positions the ethylene residues relative to the neighboring propylene residues. 13 C NMR can be used to determine the randomness and narrow composition distribution of the crystallizable copolymers. To produce crystallizable copolymers with the required amount of randomness and narrow composition distribution, it would be desirable to use (1) a single-site catalyst and (2) a well-mixed loop polymerization reactor that allows only a single polymerization environment for substantially all of the polymer chains of the appropriate propylene-based polymer. Suitable propylene-ethylene copolymers are described in US Pat. No. 6,635,715, the contents of which are incorporated herein by reference.

[0038] Commercially available examples of polymers formed by the processes and plants of the present disclosure include Vistamaxx™ copolymers from ExxonMobil Chemical Company, Tafmer™ elastomers from Mitsui Chemicals, and Versify™ elastomers from Dow Chemical Company. For example, Vistamaxx™ is a propylene-based elastomer that enhances the performance and processability of films, compounds, nonwovens, and molded / extruded products. Vistamaxx™ free-flowing pellets are easy to incorporate, and their broad compatibility allows for dry blending operations. Vistamaxx™ offers a wide range of applications, such as: 1) nonwovens (elasticity, softness, and toughness, delivered with drop-in processing capabilities); 2) films (elasticity, sealability, toughness, and tack); and 3) polymer modification and compounding (impact strength, clarity, flexibility / stiffness, softness, high filler loading). Vistamaxx™ copolymers are copolymers of propylene and ethylene. Vistamaxx™ is a propylene-rich (>80%), semi-crystalline material with a high amorphous content. Vistamaxx™ polymer synthesis is typically based on ExxonMobil Chemical's Exxpol™ technology. Vistamaxx™ 6102 ("VM6102") has a viscosity of 0.862 g / cm 3 %, a melt index of 1.4 g / 10 min (at 190° C. and 2.16 kg), an MFR of 3 g / 10 min, and an ethylene content of 16 wt %. Vistamaxx™ 3980 propylene-ethylene performance polymer ("VM3980") is available from ExxonMobil Chemical Company. VM3980 has an ethylene content of 9 wt%, with the remainder being propylene. Properties of VM3980 include: 0.879 g / cm 3 density (ASTM D1505); melt index of 3.6 g / 10 min (ASTM D1238; 190°C, 2.16 kg); melt mass flow rate of 8 g / 10 min (230°C, 2.16 kg); Shore D hardness (ASTM D2240) of 34; and Vicat softening temperature (VST) of 77.3°C.

[0039] Vistamaxx™ 6502 (VM6502) is a polymer with isotactic propylene repeat units in a random ethylene distribution; the polymer has a density of 0.865 g / cm 3 density of 45.2 g / 10 min; melt mass flow rate (230° C., 2.16 kg); and ethylene content of 13.1 wt %. Vistamaxx™ 3000 propylene-ethylene performance polymer ("VM3000") is available from ExxonMobil Chemical Company. VM3000 has 11 wt% ethylene, the remainder propylene. Properties of VM3000 include: 0.873 g / cm 3 density (ASTM D1505); melt index (ASTM D1238; 190°C, 2.16 kg) of 3.7 g / 10 min; melt mass flow rate (230°C, 2.16 kg) of 8 g / 10 min; Shore D hardness (ASTM D2240) of 27; and Vicat softening temperature (VST) of 65.1°C. Vistamaxx™ 3588 propylene-ethylene performance polymer ("VM3588") is available from ExxonMobil Chemical Company. VM3588 has an ethylene content of 4 wt%, with the remainder being propylene. Properties of VM3588 include: 0.889 g / cm 3 density (ASTM D1505); melt mass flow rate (230°C, 2.16 kg) of 8 g / 10 min; Shore D hardness (ASTM D2240) of 50; and Vicat softening temperature (VST) of 103°C. Vistamaxx™ 6202 ("VM6202") has a viscosity of 0.863 g / cm 3 %, a melt index of 9.1 g / 10 min (at 190° C. and 2.16 kg), an MFR of 20 g / 10 min, and an ethylene content of 15 wt %. Vistamaxx™ 3020 ("VM3020") has a viscosity of 0.874 g / cm 3%, a melt index of 1.1 g / 10 min (at 190° C. and 2.16 kg), an MFR of 3 g / 10 min, and an ethylene content of 11 wt %. The disclosed plants and processes provide for transitioning between different grades of polymer, e.g., Vistamaxx™ grades of polymer, with reduced amounts of off-specification (e.g., degraded polymer and / or non-degraded polymer outside the desired specification range) compared to conventional plants and processes in a manner that also results in reduced transition time between polymer grades and reduced amounts of recycle polymer in the recycle line.

[0040] Plant and Process Flow FIG. 1 is a plant (100) and process flow for polymerization and devolatilization according to an embodiment. As shown in FIG. 1 , a monomer stream (101) and a catalyst compound stream (102) may be introduced into a plant 100 and mixed to form a solution. A solvent (e.g., isohexane) may also be present. The solution of monomer and catalyst compound may travel through a cooler or heater (103) to reach the appropriate temperature. The cooled or heated solution of monomer and catalyst compound may then be pumped via a pump (104) to a first heat exchanger (105) within the reaction zone. Prior to introduction into the first heat exchanger, the catalyst compound may be contacted with an activator (not shown) as described herein to form a catalyst system. In some embodiments, the catalyst compound is contacted with an activator immediately prior to entering the first heat exchanger.

[0041] The catalyst system contacts the monomer in solution in the first heat exchanger (105), resulting in polymer. The monomer, catalyst system, and polymer may flow through the first heat exchanger (105) in a cross-flow direction relative to the first heat exchanger (105). A portion of the monomer, catalyst system, and polymer exiting the first heat exchanger (105) may be recycled back to the first heat exchanger (105), while another portion of the monomer, catalyst system, and polymer exiting the first heat exchanger (105) may be pumped by another pump (106) to a second heat exchanger (107) within the reaction zone. A portion of the monomer, catalyst system, and polymer exiting the second heat exchanger (107) may be recycled back to the second heat exchanger (107), while another portion of the monomer, catalyst system, and polymer exiting the second heat exchanger (107) may be transferred to a phase separator / devolatilizer vessel (14). Additionally or alternatively, an activator may be introduced into the recycle stream (not shown). Although the first heat exchanger (105) and the second heat exchanger (107) are shown in series, they may alternatively be in parallel.

[0042] In the phase separator (14), the monomer and / or solvent are separated from the polymer. A concentrated polymer solution can exit the bottom of the phase separator (14) and pass through a stream splitter (70). This stream splitter (70) distributes the concentrated polymer solution into a first stream that is transferred via line (72) to the low-pressure separator (34). In the low-pressure separator (34), evaporated solvent and monomer are separated from the further concentrated polymer solution exiting the phase separator (14). The stream splitter (70) also distributes the concentrated polymer solution into a second stream (recycle stream), which is transferred via line (74) to line (11) at a location upstream of the heat exchanger (not shown) for mixing with the reactor effluent. In some embodiments, a third separator (not shown) may be utilized. The third separator is typically operated at a lower pressure and a higher temperature than the separator (34). In some embodiments, the third separator may be operated at a pressure of about 667 Pa (5 Torr) to about 5333 Pa (40 Torr) and / or a temperature of about 130°C to about 220°C.

[0043] A heater (109) in line (72) forms a heated concentrated polymer solution. A portion of the heated concentrated polymer solution can be recycled to the phase separator (14). The remaining portion of the heated concentrated polymer solution can be further heated in a heater (110) in line (72) to maintain the heated concentrated polymer solution in a molten phase before being transferred to the low-pressure separator (34) to remove any residual monomer and / or solvent from the heated concentrated polymer solution. A more concentrated polymer solution (up to about 100% polymer) exits the bottom of the low-pressure separator (34), which can be either (1) processed in a third stage devolatilization (e.g., a low-pressure separator) (not shown) or (2) mixed with additional suitable additives (112) and cooled in a cooler (113) before being sent to pelletization and packaging. Similarly, the more concentrated polymer solution exits the third stage devolatilization vessel (not shown) and can be mixed with appropriate additives (112), cooled in a cooler (113), and then sent for pelletization and packaging.

[0044] Conditions in the phase separator (14) during devolatilization can include a temperature of about 150° C. to about 180° C. (e.g., average temperature of the interior volume of the phase separator), a pressure of about 75 psig (0.517 MPa) to about 150 psig (1.034 MPa), and / or a mass flow rate (e.g., of the first and / or second concentrated polymer solution) of about 200 tons (Mlb) / hr to about 1000 tons (Mlb) / hr, e.g., about 250 tons (Mlb) / hr to about 775 tons (Mlb) / hr. The polymer content of the reactor effluent entering the phase separator (14) can be about 10 wt % to about 25 wt %. The polymer content of the effluent of phase separator (14) entering low-pressure separator (34) is from about 25 wt% to about 45 wt%. Low-pressure separator (34) may be operated at a temperature of from about 180°C to about 200°C and a pressure of from about 0.1724 MPa (25 psig) to about 0.345 MPa (50 psig). The polymer content of the effluent exiting the low-pressure separator (34) can be from about 80 wt% to about 95 wt%, for example, from about 88 wt% to about 91 wt%. If a third-stage devolatilization is performed, the third separator (not shown) can be operated at a temperature of from about 200°C to about 220°C and a pressure of from about 20 torr (0.39 psig) to about 50 torr (0.97 psig). The effluent exiting the third separator can have less than about 500 wppm volatile organic compounds (VOCs).

[0045] The monomer and solvent exiting the top of the phase separator (14) may then be cooled in a cooler (114) and transferred to a condenser (115). The concentrated monomer and / or solvent exit the bottom of the condenser (115) and transferred to a mixed feed drum (120) so that it can be fed back into the system. Non-condensable gases (e.g., hydrogen gas, ethylene gas) exit the top of the condenser (115) and may be transferred to a compressor (118) and another cooler (119) to convert the gas to a liquid, which may then be transferred to the mixed feed drum (120) for reuse in the system. Similarly, the monomer and / or solvent exiting the top of the low-pressure separator (34) may pass through a compressor (116), another cooler (117), compressor (118), and cooler (119) to form a liquid, which may then be transferred to the mixed feed drum (120) for reuse in the system.

[0046] Non-limiting polymerization example Table 1 shows exemplary polymerization processes for making low molecular weight plastomers, high molecular weight elastomers, and high propylene content ethylene copolymers polymerized as described above. In some embodiments, the plant is operated at one or more of the conditions shown in Table 1.

[0047] [Table 1]

[0048] To produce plastomers using the plant of Figure 1, the feed temperature can be reduced to 0°C using a heater / cooler (103). An aluminum alkyl is added as a scavenger in an amount appropriate to the poison content of the feed. The pressure is increased to 120 bar using a centrifugal pump. Next, a feed containing primarily solvent and ethylene with propylene, butene, hexene, or octene comonomers at partial pressures of up to 50 bar enters the first heat exchanger (105) (e.g., the first reactor in a series of reactors). Catalyst and activator are added to the first heat exchanger (105 / 107) in amounts that result in the desired polymerization temperature, which is related to the desired molecular weight of the polymer being formed. The heat of polymerization is applied without the use of hydrogen (although H2 may be used) to raise the temperature to 150-200°C to form the plastomer. At the outlet of the second series reactor, the polymer concentration is in the range of 10-25 wt%. Water is then fed via a line (not shown) to quench the polymerization reaction, which would otherwise continue in the presence of residual catalyst, unreacted monomer, and elevated temperature. The heat exchangers initially raise the temperature, and the concentrated polymer solution in the recycle line (74) (in addition to the heat exchangers located within the phase separator (14), described in more detail below) causes a further temperature increase. A rapid pressure drop occurs as the polymerization mixture enters the phase separator (14) through the letdown valve (18) (FIG. 2), with the pressure rapidly dropping. The pressure difference between the reactor pump outlet and the letdown valve (18) outlet is responsible for forcing the feed and polymerization mixture to flow through the heat exchangers (105 / 107) and the line (11) containing the heat exchanger (12).

[0049] Comparing the use of this plant to the row marked "Elastomer" in Table 1, it can be seen that although the polymerization temperature is lower for the plastomer and the reactor effluent coming out of the reactor is smaller (its viscosity will be similar to that of the plastomer), the same separation process and plant can be used to give somewhat lower production volumes (reflecting the reduced efficiency of the polymerization process at lower temperatures). With two reactors in series, it may be preferable for the first reactor to operate at a temperature of 0-110°C and the second reactor to operate at a temperature of 40-140°C; for example, the first reactor to operate at a temperature of 10-90°C and the second reactor to operate at a temperature of 50-120°C; for example, the first reactor to operate at a temperature of 20-70°C and the second reactor to operate at a temperature of 60-110°C. With proper control of process conditions and poison levels, temperatures of this order of magnitude can be obtained using only one reactor or even two reactors under identical process conditions. The same is true for the row in Table 1 marked "Major Propylene Content Copolymer" where the temperature is lowered to allow the less reactive propylene monomer to form a sufficiently high molecular weight.

[0050] The disclosed plants and processes enable polymerization and subsequent polymer separation to yield polymers of a wide variety of average molecular weights and comonomer contents over a wide range of temperatures, using catalysts suitable for operation at high and low operating temperatures. The disclosed process plants are capable of producing plastomers, elastomers, and / or predominantly propylene content copolymers by simply varying the polymerization starting materials (e.g., catalyst, monomer, and / or comonomer) and process conditions.

[0051] Figure 2 shows a portion of a plant (100) during normal operation mode according to an embodiment. As shown in Figure 2, line (11) carries reactor effluent that is mixed with concentrated polymer solution in recycle line (74). The reactor effluent and concentrated polymer solution can be mixed directly and enter line (11). Alternatively, as shown in Figure 2, after mixing via mixer (76), the mixture can continue to move via line (11) to heat exchanger (12). As mentioned above, the plant of the present disclosure may be operated under a normal operating mode in which the concentrated polymer solution in recycle line (74) is mixed with the reactor effluent in line (11). Alternatively, during a transition mode, only the reactor effluent is fed to phase separator (14) via line (11), and the recycle of the concentrated polymer solution is stopped. For example, valves (310a) and / or (310b) (each shown in an open position in FIG. 2) may be in a closed position to stop mixing of the concentrated polymer solution in recycle line (74) with the reactor effluent in line (11). A transition mode may be implemented to transition between polymer grades or between entirely different polymers.

[0052] During normal operation or transition mode, the reactor effluent in line (11) entering mixer (76) is at a temperature of from about 130°F to about 330°F, for example, from about 140°F to about 320°F, and at a pressure of from about 550 psig to about 800 psig, for example, from about 580 psig to about 4. The pressure may be 482 MPa (650 psig), a mass flow rate of about 181,440 t (400 Mlb) / hr to about 317,520 t (700 Mlb) / hr, e.g., about 226,800 t (500 Mlb) / hr to about 272,160 t (600 Mlb) / hr, a steam content of about 0 wt%, and / or a polymer content of about 5 wt% to about 35 wt%, e.g., about 10 wt% to about 30 wt%. The concentrated polymer solution in recycle line (74) (from stream splitter (70)) entering mixer (76) is maintained at a temperature of from about 200°F to about 300°F, e.g., from about 215°F to about 280°F, and at a pressure of from about 550 psig to about 800 psig, e.g., from about 580 psig. The pressure may be from about 158,760 t (350 Mlb) / hr to about 285,768 t (630 Mlb) / hr, e.g., from about 204,120 t (450 Mlb) / hr to about 244,944 t (540 Mlb) / hr, a steam content of about 0 wt%, and / or a polymer content of from about 20 wt% to about 60 wt%, e.g., from about 25 wt% to about 50 wt%.

[0053] From mixer (76), the reactor effluent (or a mixture of reactor effluent and concentrated polymer solution) is transferred to heat exchanger (12). During normal operating mode (when the reactor effluent and concentrated polymer solution are mixed), the mixture of reactor effluent and concentrated polymer solution in line (11) between mixer (76) and heat exchanger (12) is maintained at a temperature of from about 150°F to about 310°F, for example, from about 180°F to about 280°F, and a pressure of from about 550 psig to about 800 psig, for example, about 3. The pressure may be from about 999 MPa (580 psig) to about 4.482 MPa (650 psig), a mass flow rate from about 362,880 t (800 Mlb) / hr to about 544,320 t (1200 Mlb) / hr, e.g., from about 464,940 t (1025 Mlb) / hr to about 487,620 t (1075 Mlb) / hr, a steam content of about 0 wt%, and / or a polymer content of about 10 wt% to about 30 wt%, e.g., from about 18 wt% to about 22 wt%. During the transition mode (where the reactor effluent and concentrated polymer solution are not mixed), the reactor effluent in line (11) between mixer (76) and heat exchanger (12) is at a temperature of from about 130°F to about 330°F, for example, from about 140°F to about 320°F, and at a pressure of from about 550 psig to about 800 psig, for example, about 599 MPa. The pressure may be from about 80 psig (1000 psi) to about 650 psig (4482 MPa), a mass flow rate from about 400 Mlb / hr to about 700 Mlb / hr (181,440 t) / hr, e.g., from about 500 Mlb / hr to about 600 Mlb / hr (226,800 t) / hr, a steam content of about 0 wt%, and / or a polymer content of from about 5 wt% to about 35 wt%, e.g., from about 10 wt% to about 30 wt%.

[0054] From the heat exchanger (12), the mixture of reactor effluent and concentrated polymer solution in line (11) is transferred to letdown valve (18) from heat exchanger (12). During normal operating mode, the mixture of reactor effluent and concentrated polymer solution in line (11) transferred from heat exchanger (12) to letdown valve (18) is maintained at a temperature of from about 220°F to about 360°F, for example, from about 240°F to about 340°F, and a pressure of from about 400 psig to about 600 psig, for example, about 435 psi. a mass flow rate of from about 400 Mlb / hr to about 1100 Mlb / hr, for example from about 500 Mlb / hr to about 1060 Mlb / hr, a steam content of from about 0 wt % to about 1 wt %, for example about 0 wt %, and / or a polymer content of from about 10 wt % to about 50 wt %, for example from about 15 wt % to about 40 wt %. During the transfer mode, the reactor effluent in line (11) transferred from heat exchanger (12) to letdown valve (18) is maintained at a temperature of from about 220°F to about 350°F, e.g., from about 240°F to about 330°F, and at a pressure of from about 400 psig to about 600 psig, e.g., from about 435 psig to about 3792 MPa. a (550 psig), a mass flow rate of about 400 Mlb / hr to about 600 Mlb / hr, for example about 450 Mlb / hr to about 560 Mlb / hr, a steam content of about 0 wt % to about 1 wt %, for example about 0 wt %, and / or a polymer content of about 5 wt % to about 35 wt %, for example about 10 wt % to about 30 wt %.

[0055] Letdown valve (18) transfers the mixture of reactor effluent and concentrated polymer solution in line (11) to phase separator (14). During normal operating mode, the mixture of reactor effluent and concentrated polymer solution transferred from letdown valve (18) to phase separator (14) is maintained at a temperature of from about 170°F to about 300°F, for example, from about 200°F to about 270°F, and at a pressure of from about 50 psig to about 200 psig, for example, from about 70 psig to about 1.1 MPa. The pressure may be 72 MPa (170 psig), a mass flow rate of about 158,760 t (350 Mlb) / hr to about 498,960 t (1100 Mlb) / hr, e.g., about 181,440 t (400 Mlb) / hr to about 498,960 t (1100 Mlb) / hr, a steam content of about 10 wt% to about 60 wt%, e.g., about 15 wt% to about 50 wt%, and / or a polymer content of about 10 wt% to about 50 wt%, e.g., about 15 wt% to about 40 wt%. During the transition mode, the reactor effluent in line (11) transferred from letdown valve (18) to phase separator (14) is maintained at a temperature of from about 170°F to about 300°F, for example, from about 190°F to about 280°F, and at a pressure of from about 50 psig to about 200 psig, for example, from about 60 psig to about 1172 MPa. 170 psig), a mass flow rate of about 400 to about 700 metric tonnes / hour, e.g., about 500 to about 600 metric tonnes / hour, a steam content of about 10 wt% to about 50 wt%, e.g., about 20 to about 40 wt%, and / or a polymer content of about 5 to about 35 wt%, e.g., about 10 to about 30 wt%.

[0056] From the phase separator (14), the concentrated polymer solution formed in the phase separator (14) is transferred via line (302) to pump (304). During normal operation mode and / or transition mode, the concentrated polymer solution in line (302) transferred from the phase separator (14) to pump (304) may be at a temperature of from about 170°F to about 300°F, for example, from about 200°F to about 270°F, a pressure of from about 50 psig to about 200 psig, for example, from about 65 psig to about 160 psig, and a pressure of from about It may have a mass flow rate of from 200 Mlb (90,720 t) / hr to about 800 Mlb (362,880 t) / hr, for example from about 220 Mlb (99,792 t) / hr to about 1060 Mlb (480,816 t) / hr, for example from about 220 Mlb (99,792 t) / hr to about 760 Mlb (344,736 t) / hr, a steam content of from about 0 wt% to about 1 wt%, for example about 0 wt%, and / or a polymer content of from about 20 wt% to about 70 wt%, for example from about 25 wt% to about 60 wt%.

[0057] From pump (304), concentrated polymer solution is transferred via line (306) to stream splitter (70). During normal operation and / or transition modes, the concentrated polymer solution in line (306) transferred from pump (304) to stream splitter (70) may be at a temperature of from about 170°F to about 300°F, for example, from about 200°F to about 270°F, and at a pressure of from about 500 psig to about 800 psig, for example, from about 550 psig to about 750 psig. a mass flow rate of from about 200 to about 800 t / hr, for example from about 220 to about 1060 t / hr, for example from about 220 to about 760 t / hr; a steam content of from about 0 wt% to about 1 wt%, for example from about 0 wt%; and / or a polymer content of from about 20 to about 70 wt%, for example from about 25 to about 60 wt%. From stream splitter (70), the concentrated polymer solution in line (72) is transferred via line (72) to separator (34). During normal operation mode and / or transition mode, the concentrated solution phase in line (72) transferred from stream splitter (70) to separator (34) may be at a temperature of from about 200°F to about 300°F, for example, from about 220°F to about 280°F, and at a pressure of from about 500 psig to about 800 psig, for example, about 550 psig. ) to about 5.171 MPa (750 psig), a mass flow rate of about 90,720 t (200 Mlb) / hr to about 158,760 t (350 Mlb) / hr, for example about 99,792 t (220 Mlb) / hr to about 122,472 t (270 Mlb) / hr, a steam content of about 0 wt % to about 1 wt %, for example about 0 wt %, and / or a polymer content of about 20 wt % to about 70 wt %, for example about 25 wt % to about 60 wt %.

[0058] FIG. 3A illustrates a phase separator (14) of a plant (100) according to an embodiment. As shown in FIG. 3A, the phase separator (14) is a static devolatilizer. The phase separator (14) includes a heat exchanger (400) and an inlet (410) for receiving an effluent (402) (e.g., reactor effluent or a mixture of reactor effluent and concentrated polymer solution) from a pressure letdown valve (18) via a line (11). As shown in FIG. 3A, the heat exchanger (400) is partially disposed within the phase separator (14), but it may alternatively be disposed entirely within the phase separator (14). The phase separator (14) includes a vessel (403) for receiving a first concentrated polymer solution (421). The vessel (403) includes a lower sump area (404) for collecting a second concentrated polymer solution (422). The vessel (403) has an upper region (405) for discharging the volatile material (406). The vessel (403) has a central region (407) between the lower sump region (404) and the upper region (405). A discharge pump (408) in fluid communication with the lower sump region (404) discharges the second concentrated polymer solution (422) from the vessel (403). An extraction line (409) enables the discharge of the volatile material (406) from the vessel (403), the extraction line (409) being located in the upper region (405) of the phase separator (14), for example, the extraction line (409) being in the top third of the phase separator (14). The heat exchanger (400) has a volatiles discharge area (434) for discharging the volatiles (406) towards the extraction line (409).

[0059] A discharge opening (424) of the heat exchanger (400) discharges the first concentrated polymer solution (421) downward toward the lower sump region (404) and toward a second heat exchanger (500) configured to receive the first concentrated polymer solution (421). The second heat exchanger (500) is configured to receive the first concentrated polymer solution (421) via an inlet (520) (which is an inner transition) and provide heat exchange to the first concentrated polymer solution (421) to form a second concentrated polymer solution (422) having a reduced volatile content relative to the first concentrated polymer solution (421). The second concentrated polymer solution (422) can exit the heat exchanger (500) via an outlet (530) (which is an outer transition) and travel toward the lower sump region (404). The separated volatiles produced by the second heat exchanger (500) may exit the second heat exchanger (500) at outlet (540) and travel towards the upper region (405) and ultimately the extraction line (409).

[0060] Heat exchanger (400) and heat exchanger (500) may independently be operated at a temperature of from about 170°F to about 330°F, for example, from about 215°F to about 300°F, a pressure of from about 50 psig to about 200 psig, for example, from about 60 psig to about 170 psig, and / or a mass flow rate of from about 200 ml / hr to about 800 ml / hr, for example, from about 250 ml / hr to about 760 ml / hr. Heat exchanger (400) and heat exchanger (500) may independently be operated at 10,550 MJ (10 MMBtu) / hr to about 31,650 MJ (30 MMBtu) / hr, for example, from about 15,825 MJ (15 MMBtu) / hr to about 26,375 MJ (25 MMBtu) / hr, for example, from about 18,990 MJ (18 MMBtu) / hr to about 23,210 MJ (22 MMBtu) / hr. "MMBtu / hr" refers to Millions of British Thermal Units (MBUs). Units / hour. Because the heat exchanger is utilized in addition to heat exchanger 12, heat exchanger 12 can be operated at a lower heat input than conventional heat exchangers in conventional recycle lines, which often operate at about 60 MBtu / hr. For example, heat exchanger 12 can be operated at about 25 MBtu / hr to about 50 MBtu / hr, e.g., about 35 MBtu / hr to about 47,475 MJ / hr, e.g., about 35 MBtu / hr to about 40 MBtu / hr.

[0061] A phase separator having one or more heat exchangers can provide improved devolatilization, particularly for highly viscous polymer products containing large amounts of volatiles and / or when the specifications for the final product allow for only very low concentrations of residual volatiles. The use of a first heat exchanger and a second heat exchanger, each disposed (partially or completely) within the phase separator, can result in a reduction in the volatile content of the second concentrated polymer phase exiting the phase separator (compared to the use of only one or no heat exchangers disposed within the phase separator). Additionally, the heat exchanger of the present disclosure may have a bundled tube-tube design, e.g., 8000 m 2 Compared to conventional tube bundles, the heat exchangers of the present disclosure provide a significant distribution of the reactor effluent (or a mixture of reactor effluent and concentrated polymer solution) to increase the heat transfer surface area and gas-liquid interface of the reactor effluent (or a mixture of reactor effluent and concentrated polymer solution). Conditions in the phase separator (14) during devolatilization can include a temperature of about 150° C. to about 180° C. (e.g., average temperature of the interior volume of the phase separator), a pressure of about 75 psig to about 150 psig, and / or a mass flow rate (e.g., of the first and / or second concentrated polymer solutions) of about 200 ml / hr to about 1000 ml / hr, e.g., about 250 ml / hr to about 775 ml / hr. The second concentrated polymer solution (422) can be transferred from the phase separator (14) via line (302) to pump (304) as described above.

[0062] FIG. 3B illustrates a phase separator (14) of a plant (100) according to an embodiment. As shown in FIG. 3B, the phase separator (14) is a static devolatilizer. The phase separator (14) includes an effluent (402) and an inlet manifold (410) for receiving the effluent (402) (e.g., reactor effluent or a mixture of reactor effluent and concentrated polymer solution) from a pressure letdown valve (18) via line (11). As shown in FIG. 3B, the inlet manifold (410) is disposed within the phase separator (14) and has a plurality of outlets (480) configured to deliver the effluent (402) to the interior cavity of the phase separator (14). For example, the phase separator (14) includes a vessel (403) for receiving a first concentrated polymer solution (421). The vessel (403) has a lower sump area (404) for collecting a second concentrated polymer solution (422). The vessel (403) has an upper region (405) for discharging the volatile material (406). The vessel (403) has a central region (407) between the lower sump region (404) and the upper region (405). A discharge pump (408) in fluid communication with the lower sump region (404) discharges the second concentrated polymer solution (422) from the vessel (403). An extraction line (409) enables the discharge of the volatile material (406) from the vessel (403), the extraction line (409) being located in the upper region (405) of the phase separator (14), for example, the extraction line (409) being in the top third of the phase separator (14).

[0063] The inlet manifold (410) has a volatile material discharge region (434) for discharging the volatile materials (406) toward the extraction line (409). An outlet (480) of the inlet manifold (410) discharges the first concentrated polymer solution (421) downward toward the lower sump region (404) and a heat exchanger (500) configured to receive the first concentrated polymer solution (421). The heat exchanger (500) receives the first concentrated polymer solution (421) via one or more inlets (not shown) and provides heat exchange to the first concentrated polymer solution (421) to form a second concentrated polymer solution (422) having a reduced volatile material content relative to the first concentrated polymer solution (421). The second concentrated polymer solution (422) may exit the heat exchanger (500) via one or more outlets (not shown) and travel toward the lower sump region (404). The separated volatiles produced by the second heat exchanger (500) may exit the second heat exchanger (500) at one or more outlets (not shown) and travel towards the upper region (405) and ultimately the extraction line (409). Heat exchanger (500) may be operated at a temperature of from about 170°F to about 330°F, for example from about 215°F to about 300°F, a pressure of from about 50 psig to about 200 psig, for example from about 60 psig to about 170 psig, and / or a mass flow rate of from about 200 ml / hr to about 800 ml / hr, for example from about 250 ml / hr to about 760 ml / hr. Heat exchanger (500) may be operated at 10,550 MJ (10 MMBtu) / hr to about 31,650 MJ (30 MMBtu) / hr, e.g., about 15,825 MJ (15 MMBtu) / hr to about 26,375 MJ (25 MMBtu) / hr, e.g., about 18,990 MJ (18 MMBtu) / hr to about 23,100 MJ (22 MMBtu) / hr. Because this heat exchanger is utilized in addition to heat exchanger (12), heat exchanger (12) of FIG. 1 may be operated at a lower heat input than conventional heat exchangers in conventional recycle lines, which often operate at about 63,300 MJ (60 MMBtu) / hr. For example, heat exchanger (12) can be operated at from about 26,375 MJ (25 MMBtu) / hr to about 52,750 MJ (50 MMBtu) / hr, such as from about 36,925 MJ (35 MMBtu) / hr to about 47,475 MJ (45 MMBtu) / hr, for example, from about 36,925 MJ (35 MMBtu) / hr to about 47,475 MJ (45 MMBtu) / hr.

[0064] A phase separator having one or more heat exchangers can provide improved devolatilization, especially for highly viscous polymer products containing large amounts of volatiles and / or when the specifications for the final product allow for only very low concentrations of residual volatiles. The use of a heat exchanger disposed within the phase separator can result in a reduction in the volatile content of the second concentrated polymer phase exiting the phase separator (compared to when a heat exchanger disposed within the phase separator is not used). Additionally, the heat exchanger of the present disclosure may have a bundled tube-tube design, e.g., 8000 m 2 Compared to conventional tube bundles, the heat exchangers of the present disclosure provide a significant distribution of the reactor effluent (or a mixture of reactor effluent and concentrated polymer solution) to increase the heat transfer surface area and gas-liquid interface of the reactor effluent (or a mixture of reactor effluent and concentrated polymer solution). Conditions in the phase separator (14) during devolatilization can include a temperature of about 150° C. to about 180° C. (e.g., average temperature of the interior volume of the phase separator), a pressure of about 75 psig to about 150 psig, and / or a mass flow rate (e.g., of the first and / or second concentrated polymer solutions) of about 200 ml / hr to about 1000 ml / hr, e.g., about 250 ml / hr to about 775 ml / hr. The second concentrated polymer solution (422) can be transferred from the phase separator (14) via line (302) to pump (304) as described above.

[0065] Figure 4 illustrates a heat exchanger (550) that can be used as the heat exchanger of Figure 3A according to an embodiment. The heat exchanger (550) can be the heat exchanger (400) and / or the heat exchanger (500) of Figure 3. As shown in Figure 4, the heat exchanger (550) includes a central body (510), two inner transition portions (520), two outer transition portions (530), and three pipe connections (540). One of the two inner transition portions (520) extends from a first end (520a) of the central body (510), and the other extends from a second end (520b) of the central body (510). Each of the two transition portions (530) extends from either outer end (520b) of the respective inner transition portion (520). Each connection portion (540) is integrally formed with the outer envelope surface of one of the first and second ends (530b, 530c) of the respective outer transition portion (530) and has a pipe wall portion extending therefrom. The pipe connections (540) are circular and can be adapted to (A) receive the reactor effluent (or a mixture of the reactor effluent and concentrated polymer solution), (B) provide an outlet for volatile materials to the phase separator vessel (403), or (C) provide an outlet for the concentrated polymer solution (422). The heat exchanger (550) (e.g., components of the heat exchanger (550), such as the central body (510)) can be formed of steel or a steel alloy. The heat exchanger (550) may have multiple channels (not shown) disposed therein. The multiple channels may form a checkerboard pattern, for example, as described in U.S. Publication No. 2020 / 0300561, the entire contents of which are incorporated herein by reference. The inner transition portion (520) has a length L in a major direction that is at least three times the maximum width W of any channel disposed within the central body (510).

[0066] Alternatively, the heat exchanger may be a plate-type heat exchanger, such as the heat exchanger shown in FIG. 3B. The plate-type heat exchanger may include a plurality of first heat exchanger plates and a plurality of second heat exchanger plates, which are interconnected and arranged side by side such that a first inter-plate space is formed between each pair of adjacent first and second heat exchanger plates, and a second inter-plate space is formed between each pair of adjacent second and first heat exchanger plates. The first inter-plate spaces and the second inter-plate spaces are spaced apart and arranged in alternating order within the plate package. Each heat exchanger plate essentially has at least a first porthole and a second porthole, where the first porthole forms a first inlet channel to the first inter-plate space and the second porthole forms a first outlet channel from the first inter-plate space. For example, the plate heat exchanger may have a first outlet for the volatiles outlet and a second outlet for the concentrated polymer solution (421) or (422).

[0067] 5-7 show a plate heat exchanger (600). The plate heat exchanger (600) comprises a plurality of heat exchanger plates (601) forming a plate package (602), each of which includes a main extension plane p (see FIG. 5). The heat exchanger plates (601) are pressed into a shape such that, when the plates are arranged side by side in the plate package (602), an interplate space is formed between each pair of plates (601). The interplate space may be formed in whole or in part by a spacing member, such as a gasket, provided between the plates and arranged to form a plurality of first passages (603) for the reactor effluent (or a mixture of the reactor effluent and the concentrated polymer solution) and a plurality of second passages (604) for a medium (e.g., a heating fluid). The first passages (603) are separated from the second passages (604). Furthermore, the first passages (603) and second passages (604) are arranged alongside one another in alternating order, e.g., substantially each first passage (603) is surrounded by two second passages (604).

[0068] Plate package 602 includes heat exchanger plates 601, which are connected to one another by any suitable method, such as brazing, and which are substantially identical except for one of the end plates, which in the disclosed embodiment lacks a porthole. Plate package 602 further includes four port channels 606, 607, 608, and 609. Each port channel 606, 607, 608, and 609 extends through plate 601, except for the one end plate. Two port channels (606) and (607) are in fluid communication with the first passageway (603), with port channel (606) forming a first inlet port channel and extending to a first inlet (611) for the reactor effluent (or a mixture of the reactor effluent and concentrated polymer solution), and port channel (607) forming a first outlet port channel and extending to a first outlet (612) for the volatiles and concentrated polymer solution. Two other port channels (608) and (609) are in fluid communication with the second passageway (604), with port channel (608) forming a second inlet port channel (608) and extending to a second inlet (613) for the medium (heating fluid), and port channel (609) forming a second inlet port channel and extending to a second outlet (614) for the medium. It should be noted that the plate heat exchanger device may be of a type having a different number of port channels, for example 2 or 6 port channels, and / or a different number of passages.

[0069] With the exception of one end plate, each port channel (606), (608), and (609) is formed by an opening or porthole in each heat exchanger plate (601) within the plate package (602). The portholes forming the port channels (606), (608), and (609) are circular when viewed in the direction of the port channels (606), (608), and (609). Each port channel (606), (608), and (609) is connected to a respective conduit pipe (221), (222), and (223), respectively, extending from the plate package (602) for the supply and removal of a medium (e.g., reactor effluent, a mixture of reactor effluent and concentrated polymer solution, volatiles, first / second concentrated polymer solutions, or a heating fluid). For example, pipe (221) and port channel (606) allow for the supply and transport of reactor effluent or a mixture of reactor effluent and concentrated polymer solution to first passageway (603). Pipe (622) and port channel (608) allow for the supply and transport of a medium (e.g., a heating fluid) to second passageway (604), and pipe (623) and port channel (609) allow for the discharge and transport of the medium (e.g., heating fluid) from second passageway (604). The plate package (602) has, in use, an upper end and a lower end that is below the upper end in the direction of gravity, with a first inlet (611) near the upper end and a first outlet (612) near the lower end. The second inlet (613) at the lower end operates according to the counterflow principle, while the second outlet (614) is at the upper end. It should be noted that plate heat exchangers can also be designed to operate according to the parallel flow principle.

[0070] The plate heat exchanger is arranged to allow heating of the reactor effluent (or a mixture of the reactor effluent and concentrated polymer solution) in the first passage (603) by use of a medium (heating fluid) in the second passage (604). For example, heating of the reactor effluent (or a mixture of the reactor effluent and concentrated polymer solution) results in volatile substances being removed from the reactor effluent (or a mixture of the reactor effluent and concentrated polymer solution). One or more of the heat exchanger plates may include a heat transfer region having corrugations including ridges and valleys. The port channel (607) forming the first outlet (612) includes or forms a volatiles outlet (631) positioned to allow the release of volatiles from the reactor effluent (or a mixture of the reactor effluent and the concentrated polymer solution) and a liquid outlet (632) positioned to allow the release of the concentrated polymer solution. The liquid outlet (632) is located in or near the gas outlet (631). In the first embodiment, the first outlet (612) is formed by a porthole. However, the port channel (607) is divided using a dividing element (633) extending from one end plate into the port channel (607) to form an upper volatiles outlet (631) and a lower volatiles outlet (632). In this way, the volatiles outlet (631) is separated from the concentrated polymer outlet (632).

[0071] The outlet opening of the volatile materials outlet (631) has a center point that, during normal use, is at a higher level with respect to gravity than the center point of the outlet opening of the liquid outlet (632). Figure 7 shows the dividing element (633) in solid lines extending a short distance into the port channel (607). However, the dashed lines indicate that the dividing element may extend substantially the entire length of the port channel (607). The dividing element (633) may comprise or be formed of a simple sheet that may have a convex, somewhat curved shape when viewed from the gas outlet (631). In this case, concentrated polymer on the dividing element (633) may flow outward and downward from the volatile materials outlet (631) or, preferably, the concentrated polymer outlet (632). In an alternative embodiment, the plate heat exchanger does not have a dividing element (633). The volatile material outlet (631) includes or is connectable to a volatile material release conduit (635) extending from the plate package (602) for the release and transport of volatile material. The concentrated polymer outlet (632) includes or is connectable to a release conduit (636), also extending from the plate package (602) and separate from the volatile material release conduit for the separate release and transport of concentrated polymer. The heat exchanger plates that substantially delimit each passage (603) are configured such that the transition between the first passage (603) and the port channel (607) of the first outlet (612) forms a throttling for the heated components of the reactor effluent (or a mixture of reactor effluent and concentrated polymer solution) flowing into the port channel (607). The throttling is formed by an edge region (646) that extends around at least the first outlet (612) and inwardly toward the central plane of the interplate space that forms the first passage (603).

[0072] Additional aspects The present disclosure provides, inter alia, the following aspects, each of which may be considered to include any alternative aspects as the case may be. Clause 1. A process for forming a polymer, comprising: providing a feed having one or more olefin monomers and a solvent; introducing the feed into a reactor along with a catalyst to form a reaction mixture; removing reactor effluent from the reactor; mixing the reactor effluent with the first concentrated polymer solution in a mixer or line to form a mixture; introducing the mixture into a heat exchanger to form a heated mixture; introducing the heated mixture into a pressure letdown valve followed by introducing the heated mixture into a phase separator; removing the second concentrated polymer solution from the phase separator; introducing a second concentrated polymer solution into the mixer or line; The process includes: Clause 2. The process of clause 1, wherein the reactor is a continuous stirred tank reactor. Clause 3. The process of clause 1 or 2, wherein the step of introducing the second concentrated polymer solution into the mixer or line is conducted at a rate of about 500,000 lb / hr or less.

[0073] Clause 4. A second concentrated polymer solution, a first portion being a second concentrated polymer solution introduced into a mixer or line; The second part and 4. The process of any one of clauses 1-3, further comprising introducing the second concentrated polymer solution into a stream splitter configured to distribute the second concentrated polymer solution into: The process further comprising introducing the second portion into a second phase separator. Clause 5. The process of any one of clauses 1 to 4, wherein the monomers include octene, butene, propylene, and ethylene. Clause 6. When the second concentrated polymer solution is being introduced into the mixer or line, the second concentrated polymer solution Temperatures between approximately 101.67°C (215°F) and approximately 137.78°C (280°F), Pressure of approximately 3.999 MPa (580 psig) to approximately 4.482 MPa (650 psig), Mass flow rate of approximately 204,120t (450Mlb) / hr to approximately 244,944t (540Mlb) / hr, A steam content of approximately 0 wt% to approximately 1 wt%, and Polymer content of approximately 25 wt% to approximately 50 wt% 6. The process of any one of clauses 1 to 5, comprising: Clause 7. When the heated mixture is being introduced into the pressure let-down valve, the heated mixture Temperatures between approximately 115.56°C (240°F) and approximately 171.11°C (340°F), Pressure of approximately 2.999 MPa (435 psig) to approximately 3.792 MPa (550 psig), Mass flow rate of approximately 226,800t (500Mlb) / hr to approximately 480,816t (1060Mlb) / hr A steam content of approximately 0 wt% to approximately 1 wt%, and Polymer content of approximately 15 wt% to approximately 40 wt% 7. The process of any one of clauses 1 to 6, comprising:

[0074] Article 8. Furthermore: stopping the introduction of the second concentrated polymer solution into the mixer or line; ceasing mixing of the reactor effluent with the first concentrated polymer solution; introducing the reactor effluent into a heat exchanger to form a heated reactor effluent; introducing the heated reactor effluent into a pressure letdown valve followed by introducing the heated reactor effluent into a phase separator; removing the third concentrated polymer solution from the phase separator; 8. The process of any one of clauses 1 to 7, comprising: Clause 9. When the heated reactor effluent is introduced into the pressure let-down valve, the heated reactor effluent Temperatures between approximately 115.56°C (240°F) and approximately 165.56°C (330°F), Pressure of approximately 2.999 MPa (435 psig) to approximately 3.792 MPa (550 psig), Mass flow rate of approximately 204,120t (450Mlb) / hr to approximately 254,016t (560Mlb) / hr A steam content of approximately 0 wt% to approximately 1 wt%, and Polymer content of approximately 10 wt% to approximately 30 wt% 9. The process of any one of clauses 1 to 8, comprising: Clause 10. When the mixture is introduced into the heat exchanger to form a heated mixture, the heated mixture is Temperatures between approximately 82.22°C (180°F) and approximately 137.78°C (280°F), Pressure of approximately 3.999 MPa (580 psig) to approximately 4.482 MPa (650 psig), Mass flow rate of approximately 464,940t (1025Mlb) / hr to approximately 487,620t (1075Mlb) / hr, A steam content of approximately 0 wt% to approximately 1 wt%, and having a polymer content of about 10 wt% to about 30 wt%, and During the introduction of the reactor effluent into the heat exchanger to form the heated reactor effluent, the heated reactor effluent is Temperatures of about 60°C (140°F) to about 160°C (320°F), Pressure of approximately 3.999 MPa (580 psig) to approximately 4.482 MPa (650 psig), Mass flow rate of approximately 226,800t (500Mlb) / hr to approximately 272,160t (600Mlb) / hr, A steam content of approximately 0 wt% to approximately 1 wt%, and having a polymer content of about 5 wt% to about 35 wt%, 10. The process according to any one of clauses 1 to 9.

[0075] Clause 11. When the heated mixture is introduced into the phase separator, Temperatures between approximately 83.33°C (200°F) and approximately 132.22°C (270°F), Pressure of approximately 0.483 MPa (70 psig) to approximately 1.172 MPa (170 psig), Mass flow rate of approximately 181,440t (400Mlb) / hr to approximately 498,960t (1,100Mlb) / hr Steam content of approximately 15 wt% to approximately 50 wt%, and having a polymer content of about 15 wt% to about 40 wt%, and While the heated reactor effluent is being introduced into the phase separator, Temperatures between approximately 87.78°C (190°F) and approximately 137.78°C (280°F), Pressure of approximately 0.414 MPa (60 psig) to approximately 1.172 MPa (170 psig), Mass flow rate of approximately 226,800t (500Mlb) / hr to approximately 272,160t (600Mlb) / hr, Steam content of approximately 20 wt% to approximately 40 wt%, and having a polymer content of about 10 wt% to about 30 wt%; 11. The process according to any one of clauses 1 to 10. Clause 12. When the second portion is introduced into the second phase separator, the second portion Temperatures between approximately 104.44°C (220°F) and approximately 137.78°C (280°F), Pressure of approximately 3.792 MPa (550 psig) to approximately 5.171 MPa (750 psig), Mass flow rate of approximately 99,792t (220Mlb) / hr to approximately 122,472t (270Mlb) / hr, A steam content of approximately 0 wt% to approximately 1 wt%, and Polymer content of approximately 25wt% to approximately 60wt% 12. The process of any one of clauses 1 to 11, comprising:

[0076] Clause 13. The process of any one of clauses 1-12, wherein the step of introducing the heated mixture into the phase separator is performed by introducing the heated mixture into an inlet of the phase separator, and a second heat exchanger is coupled to the inlet of the phase separator. Clause 14. The process of any one of clauses 1-13, wherein the step of introducing the heated mixture into the phase separator further comprises the step of introducing the heated mixture into a third heat exchanger disposed within the phase separator below the second heat exchanger. Clause 15. The process of any one of clauses 1-14, wherein the second heat exchanger comprises a first plurality of tubes and the third heat exchanger comprises a second plurality of tubes. Clause 16. The second heat exchanger comprises: Temperatures between approximately 101.67°C (215°F) and approximately 148.89°C (300°F), a pressure of about 0.414 MPa (60 psig) to about 1.172 MPa (170 psig), and Mass flow rate of approximately 113,400t (250Mlb) / hr to approximately 480,816t (1060Mlb) / hr 16. The process according to any one of clauses 1 to 15, wherein the process is operated by Clause 17. The third heat exchanger: Temperatures between approximately 101.67°C (215°F) and approximately 148.89°C (300°F), a pressure of about 0.414 MPa (60 psig) to about 1.172 MPa (170 psig), and Mass flow rate of approximately 113,400t (250Mlb) / hr to approximately 344,736t (760Mlb) / hr 17. The process according to any one of clauses 1 to 16, wherein the process is operated with

[0077] Clause 18. The first heat exchanger is operated at about 26,375 MJ (25 MMBtu) / hr to about 52,750 MJ (50 MMBtu) / hr; 18. The process according to any one of clauses 1 to 17. Clause 19. The second heat exchanger is operated at about 10,550 MJ (10 MMBtu) / hr to about 31,650 MJ (30 MMBtu) / hr; and the third heat exchanger is operated at about 10,550 MJ (10 MMBtu) / hr to about 31,650 MJ (30 MMBtu) / hr; 19. The process according to any one of clauses 1 to 18. Clause 20. The first heat exchanger is operated at about 36,925 MJ (35 MMBtu) / hr to about 47,475 MJ (45 MMBtu) / hr; the second heat exchanger is operated at about 18,990 MJ (18 MMBtu) / hr to about 23,100 MJ (22 MMBtu) / hr; and the third heat exchanger is operated at about 18,990 MJ (18 MMBtu) / hr to about 23,100 MJ (22 MMBtu) / hr; 20. The process according to any one of clauses 1 to 19. Clause 21. A phase separator, Temperatures between approximately 104.44°C (220°F) and approximately 148.89°C (300°F), a pressure of about 0.414 MPa (60 psig) to about 1.172 MPa (170 psig), and Mass flow rate of approximately 113,400t (250Mlb) / hr to approximately 351,540t (775Mlb) / hr 22. The process of any one of clauses 1 to 21, further comprising the step of operating with

[0078] Clause 22. A plant for forming polymers, comprising: a polymerization reactor coupled to a phase separator; a heat exchanger and a pressure letdown valve disposed between the polymerization reactor and the phase separator, the heat exchanger being connected to the polymerization reactor and the pressure letdown valve, and the pressure letdown valve being connected to the phase separator; a stream splitter coupled to the phase separator and coupled to the line at a location upstream of the heat exchanger and the pressure let-down valve; Including, plant. Clause 23. Further comprising a second phase separator coupled to the stream splitter; Plants as referred to in clause 22. Clause 24. Further comprising a vacuum devolatilizing extruder coupled to the second phase separator. Plants as referred to in clauses 22 or 23. Clause 25. Further including one or more valves coupled to the second line, the one or more valves configured to prevent flow of material in the second line from entering the first line at a location upstream of the heat exchanger and the pressure let-down valve. A plant according to any one of clauses 22 to 24. Clause 26. The phase separator includes a second heat exchanger coupled to the inlet of the phase separator. A plant according to any one of clauses 22 to 25. Clause 27. The plant of any one of clauses 22 to 26, wherein the phase separator further comprises a third heat exchanger disposed within the phase separator below the second heat exchanger.

[0079] Overall, the plants and processes of the present disclosure allow for faster transition times between polymer grades, while also reducing the amount of off-specification (e.g., degraded polymer and less recycled concentrated polymer in the recycle line) compared to conventional plants and processes. The phrases "consists essentially of" and "consisting essentially of," unless otherwise specified, do not exclude the presence of other steps, elements, or materials, whether specifically mentioned herein or not, unless such steps, elements, or materials affect the basic and novel characteristics of the disclosure, nor do they exclude impurities and variations commonly associated with the elements and materials used. For the sake of brevity, only certain ranges are explicitly disclosed herein. However, a range from any lower limit can be combined with any upper limit to describe a range not explicitly stated, and a range from any lower limit can be combined with any other lower limit to describe a range not explicitly stated, and similarly, a range from any upper limit can be combined with any other upper limit to describe a range not explicitly stated. Furthermore, any point or individual value between its endpoints is included within the range, even if not explicitly stated. Thus, any point or individual value can serve as its own lower or upper limit in combination with any other point or individual value or any other lower or upper limit to describe a range not explicitly stated. All numerical values ​​within this detailed description are modified by the term "about" to account for experimental error and variations that one of ordinary skill in the art would expect.

[0080] All documents cited herein, including any priority documents or testing procedures, are incorporated herein by reference to the extent they do not contradict this text. While forms of the disclosure have been illustrated and described, as is apparent from the foregoing general description and specific embodiments, various modifications can be made without departing from the spirit and scope of the disclosure. Accordingly, the disclosure is not intended to be limited thereby. Similarly, the term "comprising" is considered synonymous with the term "including" for purposes of U.S. law. Similarly, whenever a composition, element, or group of elements is preceded by the transitional phrase "comprising," it should be understood that we also contemplate the same composition or group of elements having the transitional phrase "consisting essentially of," "consisting of," "selected from the group of consisting of," or "is" preceding the description of the composition, element, or elements, and vice versa. While the present disclosure has been described in terms of certain embodiments and examples, those skilled in the art, having the benefit of this disclosure, may devise other embodiments that do not depart from the scope and spirit of the present disclosure. Another aspect of the present invention may be as follows. [1] A process for forming a polymer, comprising: providing a feed having one or more olefin monomers and a solvent; introducing the feed into a reactor along with a catalyst to form a reaction mixture; removing reactor effluent from the reactor; mixing the reactor effluent with a first concentrated polymer solution in a mixer or line to form a mixture; introducing the mixture into a heat exchanger to form a heated mixture; introducing the heated mixture into a pressure letdown valve followed by introducing the heated mixture into a phase separator; removing the second concentrated polymer solution from the phase separator; introducing the second concentrated polymer solution into the mixer or line; The process comprising: [2] The process according to [1] above, wherein the reactor is a continuous stirred tank reactor. [3] The process described in [1] or [2], wherein the step of introducing the second concentrated polymer solution into the mixer or line is carried out at a rate of about 227 tons (500,000 lb) / hr or less. [4] The second concentrated polymer solution, a first portion, the second concentrated polymer solution, introduced into the mixer or line; The second part and The process according to any one of [1] to [3], further comprising the step of introducing the second concentrated polymer solution into a stream splitter configured to distribute the second concentrated polymer solution into The process further comprising the step of introducing the second portion into a second phase separator. [5] The process according to any one of [1] to [4] above, wherein the monomers include octene, butene, propylene, and ethylene. [6] When the second concentrated polymer solution is introduced into the mixer or line, the second concentrated polymer solution Temperatures between approximately 101.67°C (215°F) and approximately 137.78°C (280°F), Pressure of approximately 3.999 MPa (580 psig) to approximately 4.482 MPa (650 psig), Mass flow rate of approximately 204,120t (450Mlb) / hr to approximately 244,944t (540Mlb) / hr, A steam content of approximately 0 wt% to approximately 1 wt%, and Polymer content of approximately 25 wt% to approximately 50 wt% The process according to any one of [1] to [5] above, comprising: [7] When the heated mixture is introduced into the pressure let-down valve, the heated mixture Temperatures between approximately 115.56°C (240°F) and approximately 171.11°C (340°F), Pressure of approximately 2.999 MPa (435 psig) to approximately 3.792 MPa (550 psig), Mass flow rate of approximately 226,800t (500Mlb) / hr to approximately 480,816t (1060Mlb) / hr A steam content of approximately 0 wt% to approximately 1 wt%, and Polymer content of approximately 15 wt% to approximately 40 wt% The process according to any one of [1] to [6] above, comprising: [8] Furthermore, stopping the introduction of the second concentrated polymer solution into the mixer or line; ceasing mixing of the reactor effluent with the first concentrated polymer solution; introducing the reactor effluent into the heat exchanger to form a heated reactor effluent; introducing the heated reactor effluent into the pressure letdown valve followed by introducing the heated reactor effluent into the phase separator; removing the third concentrated polymer solution from the phase separator; The process according to any one of [1] to [7] above, comprising: [9] When the heating reactor effluent is introduced into the pressure let-down valve, the heating reactor effluent is Temperatures between approximately 115.56°C (240°F) and approximately 165.56°C (330°F), Pressure of approximately 2.999 MPa (435 psig) to approximately 3.792 MPa (550 psig), Mass flow rate of approximately 204,120t (450Mlb) / hr to approximately 254,016t (560Mlb) / hr A steam content of approximately 0 wt% to approximately 1 wt%, and Polymer content of approximately 10 wt% to approximately 30 wt% The process according to any one of [1] to [8] above, comprising:

[10] When the mixture is introduced into the heat exchanger to form the heated mixture, the heated mixture is Temperatures between approximately 82.22°C (180°F) and approximately 137.78°C (280°F), Pressure of approximately 3.999 MPa (580 psig) to approximately 4.482 MPa (650 psig), Mass flow rate of approximately 464,940t (1025Mlb) / hr to approximately 487,620t (1075Mlb) / hr, A steam content of approximately 0 wt% to approximately 1 wt%, and having a polymer content of about 10 wt% to about 30 wt%, and When the reactor effluent is introduced into the heat exchanger to form the heated reactor effluent, the heated reactor effluent comprises: Temperatures of about 60°C (140°F) to about 160°C (320°F), Pressure of approximately 3.999 MPa (580 psig) to approximately 4.482 MPa (650 psig), Mass flow rate of approximately 226,800t (500Mlb) / hr to approximately 272,160t (600Mlb) / hr, A steam content of approximately 0 wt% to approximately 1 wt%, and having a polymer content of about 5 wt% to about 35 wt%, The process described in any one of [1] to [9] above.

[11] When the heated mixture is introduced into the phase separator, the heated mixture is Temperatures between approximately 83.33°C (200°F) and approximately 132.22°C (270°F), Pressure of approximately 0.483 MPa (70 psig) to approximately 1.172 MPa (170 psig), Mass flow rate of approximately 181,440t (400Mlb) / hr to approximately 498,960t (1,100Mlb) / hr Steam content of approximately 15 wt% to approximately 50 wt%, and having a polymer content of about 15 wt% to about 40 wt%, and While the heated reactor effluent is being introduced into the phase separator, the heated reactor effluent Temperatures between approximately 87.78°C (190°F) and approximately 137.78°C (280°F), Pressure of approximately 0.414 MPa (60 psig) to approximately 1.172 MPa (170 psig), Mass flow rate of approximately 226,800t (500Mlb) / hr to approximately 272,160t (600Mlb) / hr, Steam content of approximately 20 wt% to approximately 40 wt%, and having a polymer content of about 10 wt% to about 30 wt%; The process described in any one of [1] to

[10] above.

[12] When the second portion is introduced into the second phase separator, the second portion Temperatures between approximately 104.44°C (220°F) and approximately 137.78°C (280°F), Pressure of approximately 3.792 MPa (550 psig) to approximately 5.171 MPa (750 psig), Mass flow rate of approximately 99,792t (220Mlb) / hr to approximately 122,472t (270Mlb) / hr, A steam content of approximately 0 wt% to approximately 1 wt%, and Polymer content of approximately 25wt% to approximately 60wt% The process according to any one of [1] to

[11] above, comprising:

[13] The process described in any one of [1] to

[12] , wherein the step of introducing the heated mixture into the phase separator is carried out by introducing the heated mixture into an inlet of the phase separator, and a second heat exchanger is connected to the inlet of the phase separator.

[14] The process described in any one of [1] to

[13] , wherein the step of introducing the heated mixture into the phase separator further comprises the step of introducing the heated mixture into a third heat exchanger disposed below the second heat exchanger within the phase separator.

[15] The process described in any one of [1] to

[14] , wherein the second heat exchanger includes a first plurality of tubes and the third heat exchanger includes a second plurality of tubes.

[16] The second heat exchanger is Temperatures between approximately 101.67°C (215°F) and approximately 148.89°C (300°F), a pressure of about 0.414 MPa (60 psig) to about 1.172 MPa (170 psig), and Mass flow rate of approximately 113,400t (250Mlb) / hr to approximately 480,816t (1060Mlb) / hr The process according to any one of [1] to

[15] above, wherein the process is carried out by

[17] The third heat exchanger is Temperatures between approximately 101.67°C (215°F) and approximately 148.89°C (300°F), a pressure of about 0.414 MPa (60 psig) to about 1.172 MPa (170 psig), and Mass flow rate of approximately 113,400t (250Mlb) / hr to approximately 344,736t (760Mlb) / hr The process according to any one of [1] to

[16] above, wherein the process is carried out by

[18] The first heat exchanger is operated at about 26,375 MJ (25 MMBtu) / hr to about 52,750 MJ (50 MMBtu) / hr. The process according to any one of [1] to

[17] above.

[19] The second heat exchanger is operated at about 10,550 MJ (10 MMBtu) / hr to about 31,650 MJ (30 MMBtu) / hr; and the third heat exchanger is operated at about 10,550 MJ (10 MMBtu) / hr to about 31,650 MJ (30 MMBtu) / hr; The process described in any one of [1] to

[18] above.

[20] The first heat exchanger is operated at about 36,925 MJ (35 MMBtu) / hr to about 42,200 MJ (40 MMBtu) / hr; the second heat exchanger is operated at about 18,990 MJ (18 MMBtu) / hr to about 23,210 MJ (22 MMBtu) / hr; and the third heat exchanger is operated at about 18,990 MJ (18 MMBtu) / hr to about 23,210 MJ (22 MMBtu) / hr; The process described in any one of [1] to

[19] above.

[21] The phase separator, Temperatures between approximately 104.44°C (220°F) and approximately 148.89°C (300°F), a pressure of about 0.414 MPa (60 psig) to about 1.172 MPa (170 psig), and Mass flow rate of approximately 113,400t (250Mlb) / hr to approximately 351,540t (775Mlb) / hr The process according to any one of [1] to

[21] above, further comprising the step of:

[22] A plant for forming a polymer, comprising: a polymerization reactor coupled to a phase separator; a heat exchanger and a pressure letdown valve disposed between the polymerization reactor and the phase separator, the heat exchanger being connected to the polymerization reactor and the pressure letdown valve, and the pressure letdown valve being connected to the phase separator; a stream splitter coupled to the phase separator and coupled in line at a location upstream of the heat exchanger and the pressure letdown valve; The plant.

[23] The plant described in

[22] , further comprising a second phase separator coupled to the stream splitter.

[24] The plant according to

[22] or

[23] , further comprising a vacuum devolatilization extruder connected to the second phase separator.

[25] The plant described in any one of

[22] to

[24] , further comprising one or more valves connected to the second line, the one or more valves being configured to prevent the flow of material in the second line from entering the first line at a position upstream of the heat exchanger and the pressure let-down valve.

[26] The plant according to any one of

[22] to

[25] , wherein the phase separator includes a second heat exchanger connected to an inlet of the phase separator.

[27] The plant described in any one of

[22] to

[26] , wherein the phase separator further includes a third heat exchanger disposed below the second heat exchanger within the phase separator.

Claims

1. 1. A process for forming a polymer, comprising: providing a feed having one or more olefin monomers and a solvent; introducing the feed into a continuous stirred tank reactor along with a catalyst to form a reaction mixture; removing reactor effluent from the reactor; mixing the reactor effluent with a first concentrated polymer solution in a mixer or line to form a mixture; introducing the mixture into a heat exchanger to form a heated mixture; introducing the heated mixture into a pressure letdown valve followed by introducing the heated mixture into a phase separator; removing the second concentrated polymer solution from the phase separator; introducing the second concentrated polymer solution into the mixer or line; Including, The process wherein the step of introducing the heated mixture into the phase separator is performed by introducing the heated mixture into an inlet of the phase separator, and a second heat exchanger is coupled to the inlet of the phase separator.

2. 10. The process of claim 1, wherein the step of introducing the second concentrated polymer solution into the mixer or line is carried out at a rate of 227 tonnes (500,000 lb) / hr or less.

3. the second concentrated polymer solution, a first portion, the second concentrated polymer solution, introduced into the mixer or line; The second part and 3. The process of claim 1 or 2, further comprising introducing the second concentrated polymer solution into a stream splitter configured to distribute the second concentrated polymer solution into: The process further comprising the step of introducing the second portion into a second phase separator.

4. 3. The process of claim 1 or 2, wherein the monomers include octene, butene, propylene, and ethylene.

5. While the second concentrated polymer solution is being introduced into the mixer or line, the second concentrated polymer solution a temperature between 215°F (101.67°C) and 280°F (137.78°C); a pressure of 3.999 MPa (580 psig) to 4.482 MPa (650 psig); Mass flow rates of 204,120 t (450 Mlb) / hr to 244,944 t (540 Mlb) / hr; A steam content of 0 wt% to 1 wt%, and Polymer content of 25 wt% to 50 wt% 3. The process of claim 1 or 2, comprising:

6. While the heated mixture is being introduced into the pressure letdown valve, the heated mixture a temperature between 240°F (115.56°C) and 340°F (171.11°C); a pressure of 2.999 MPa (435 psig) to 3.792 MPa (550 psig); Mass flow rates of 226,800 t (500 Mlb) / hr to 480,816 t (1060 Mlb) / hr; A steam content of 0 wt% to 1 wt%, and Polymer content of 15 wt% to 40 wt% 3. The process of claim 1 or 2, comprising:

7. moreover, stopping the introduction of the second concentrated polymer solution into the mixer or line; ceasing mixing of the reactor effluent with the first concentrated polymer solution; introducing the reactor effluent into the heat exchanger to form a heated reactor effluent; introducing the heated reactor effluent into the pressure letdown valve followed by introducing the heated reactor effluent into the phase separator; and removing the third concentrated polymer solution from the phase separator.

8. When the heated reactor effluent is introduced into the pressure letdown valve, the heated reactor effluent a temperature between 240°F (115.56°C) and 330°F (165.56°C); a pressure of 2.999 MPa (435 psig) to 3.792 MPa (550 psig); Mass flow rates of 204,120 t (450 Mlb) / hr to 254,016 t (560 Mlb) / hr; A steam content of 0 wt% to 1 wt%, and Polymer content of 10 wt% to 30 wt% 8. The process of claim 7, comprising:

9. When the mixture is introduced into the heat exchanger to form the heated mixture, the heated mixture temperatures between 180°F (82.22°C) and 280°F (137.78°C); a pressure of 3.999 MPa (580 psig) to 4.482 MPa (650 psig); Mass flow rates of 464,940 t (1025 Mlb) / hr to 487,620 t (1075 Mlb) / hr; A steam content of 0 wt% to 1 wt%, and having a polymer content of 10 wt % to 30 wt %; and When the reactor effluent is introduced into the heat exchanger to form the heated reactor effluent, the heated reactor effluent comprises: a temperature of 60°C (140°F) to 160°C (320°F), a pressure of 3.999 MPa (580 psig) to 4.482 MPa (650 psig); Mass flow rates of 226,800 t (500 Mlb) / hr to 272,160 t (600 Mlb) / hr; A steam content of 0 wt% to 1 wt%, and having a polymer content of 5 wt % to 35 wt %; The process of claim 7.

10. While the heated mixture is being introduced into the phase separator, the heated mixture a temperature between 200°F (83.33°C) and 270°F (132.22°C); a pressure of 0.483 MPa (70 psig) to 1.172 MPa (170 psig); Mass flow rates of 181,440 t (400 Mlb) / hr to 498,960 t (1,100 Mlb) / hr; A steam content of 15 wt% to 50 wt%, and having a polymer content of 15 wt % to 40 wt %; and While the heated reactor effluent is being introduced into the phase separator, the heated reactor effluent a temperature between 190°F (87.78°C) and 280°F (137.78°C); a pressure of 0.414 MPa (60 psig) to 1.172 MPa (170 psig); Mass flow rates of 226,800 t (500 Mlb) / hr to 272,160 t (600 Mlb) / hr; A steam content of 20 wt% to 40 wt%, and having a polymer content of 10 wt % to 30 wt %; The process of claim 7.

11. The second portion is then passed through the second phase separator. When the second portion is introduced into a temperature between 220°F (104.44°C) and 280°F (137.78°C); a pressure of 3.792 MPa (550 psig) to 5.171 MPa (750 psig); Mass flow rates of 99,792 t (220 Mlb) / hr to 122,472 t (270 Mlb) / hr; A steam content of 0 wt% to 1 wt%, and Polymer content of 25 wt% to 60 wt% 4. The process of claim 3, comprising:

12. 3. The process of claim 1 or 2, wherein introducing the heated mixture into the phase separator further comprises introducing the heated mixture into a third heat exchanger located within the phase separator below the second heat exchanger.

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