Catalyst Pre-Contact Device for Olefin Polymerization
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Solution Overview
Problem
Current olefin polymerization processes lack the ability to optimize catalyst pre-contact conditions such as temperature and time, which are crucial for enhancing polymerization performance, as existing methods do not allow for adjustable pre-contact parameters.
Innovation Solution
A catalyst pre-contact method and device that allow for adjustable pre-contact temperatures ranging from −30° C. to 40° C. and pre-contact times from 0.5 min to 70 min, using a catalyst pre-contact tank and coil with valved inlets and outlets, and multiple mini tanks in series to precisely control the pre-contact conditions, preventing backmixing and optimizing catalyst performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a catalyst pre-contact tank with stirring means is used to mix catalyst, cocatalyst and external electron donor, then sufficient mixing and pre-contact reaction is achieved, but the pre-contact temperature and time cannot be adjusted to optimize polymerization performance
Solution Approach 1:
The pre-contact device is divided into multiple sections: a pre-contact tank for initial mixing and a pre-contact coil for extended reaction. This segmentation allows different regions to serve different functions - the tank provides vigorous mixing while the coil provides controlled temperature and time conditions, thereby achieving both mixing uniformity and condition adjustability
Solution Approach 2:
The invention introduces dynamic control capabilities by equipping the pre-contact coil with temperature control means and using valved inlets/outlets to adjust residence time. This transforms the static mixing tank into a dynamic system where temperature and contact time can be precisely controlled to optimize polymerization performance
2Productivity
If the catalyst pre-contact device allows adjustment of pre-contact temperature and time, then catalyst performance is optimized, but the device complexity increases
Solution Approach 1:
The invention merges the pre-contact tank and pre-contact coil into a single integrated device. The tank handles initial mixing while the coil provides extended controlled reaction, combining both functions in one unit. This integration achieves optimized polymerization performance without requiring multiple separate equipment pieces, thereby limiting the increase in device complexity
Solution Approach 2:
The pre-contact device is designed with multi-functionality: it can perform both vigorous mixing (tank function) and controlled temperature/time reaction (coil function). The temperature control means and valved outlets provide universal adjustability for different catalyst systems and polymerization requirements, achieving high productivity through a versatile device rather than multiple specialized equipment
3Device complexity
If a single pre-contact tank is used, then the structure is simple, but backmixing of pre-contacted materials occurs
Solution Approach 1:
The pre-contact device is divided into a tank section and a coil section with distinct flow patterns. The tank provides initial mixing while the coil provides plug-flow characteristics that prevent backmixing. This segmentation maintains simple overall structure while achieving composition stability through the functional division between mixing and controlled reaction zones
Solution Approach 2:
The pre-contact coil acts as an intermediary between the mixing tank and the polymerization reactor. It receives the mixed catalyst composition from the tank and provides a controlled environment that prevents backmixing while allowing extended reaction time. This intermediary element maintains simple device structure while ensuring composition stability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables precise control of pre-contact conditions, enhancing catalyst activity, isotacticity, and melt flow index, leading to improved polymerization outcomes with a low investment cost and preventing backmixing of pre-contacted materials.
Implementation Method 1
a catalyst pre-contact device comprising a catalyst pre-contact tank and at least one catalyst pre-contact coil connected to the catalyst pre-contact tank
Implementation Method 2
The catalyst pre-contact tank has a stirring means, which is used to sufficiently mix three-agents to conduct the pre-contact reaction
Data Source
AI summary
Disclosed is a catalyst pre-contact method for the continuous polymerization of an olefin, wherein a primary catalyst, a co-catalyst and, optionally, an external electron donor are mixed and then undergo a pre-contact reaction, with the pre-contact reaction temperature being −30° C. to 35° C. and adjustable, and the pre-contact reaction time being 0.5 min to 10 min and adjustable, and the pre-contacted catalyst is brought into a catalyst prepolymerization system and then into a catalyst polymerization system, or is directly brought into the catalyst polymerization system. Further disclosed is a catalyst pre-contact device for the continuous polymerization of an olefin, which can adjust the pre-contact time and pre-contact temperature of the catalyst so that the performance of the catalyst achieves a better level according to the process.