Comonomer Bypass for Corrosion Control in High Pressure Polymerization
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Solution Overview
Problem
The production of ethylene-based polymers containing acid comonomers leads to corrosion of compressors due to the corrosive and reactive nature of these comonomers, resulting in reliability issues and downtime in the polymerization process.
Innovation Solution
A process involving the polymerization of ethylene and acid comonomers at high pressures in a reactor configuration with a pressurization device, where the acid comonomer composition is compressed and bypasses the Secondary compressor, reducing exposure and minimizing corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If acid comonomer is injected at the suction of the Secondary compressor, then the polymerization process can proceed, but the compressor suffers from corrosion and reliability issues
Solution Approach 1:
The acid comonomer is extracted from the main gas stream and compressed separately through a dedicated pressurization device, removing it from the path of the Secondary compressor. This eliminates the corrosive acid comonomer's contact with the Secondary compressor while maintaining its function in the polymerization process.
Solution Approach 2:
The compression process is segmented into two independent paths: one for the ethylene/gas stream using the Secondary compressor, and another for the acid comonomer using a separate pressurization device. This segmentation isolates the corrosive substance from the compressor that would otherwise be exposed to it.
2Ease of operation
If acid comonomer is compressed through the Secondary compressor, then the comonomer can be fed into the reactor, but the compressor experiences corrosion and downtime
Solution Approach 1:
A dedicated pressurization device acts as an intermediary for compressing the acid comonomer, taking over this function from the Secondary compressor. This intermediary device handles the corrosive substance, protecting the Secondary compressor while ensuring proper comonomer feeding to the reactor.
3Reliability
If the acid comonomer composition is compressed in the pressurization device to high pressure, then the comonomer can bypass the Secondary compressor, but additional equipment is required
Solution Approach 1:
The acid comonomer compression function is extracted from the main compressor system and placed in a dedicated pressurization device. While this adds equipment, it eliminates the recurring maintenance and downtime associated with compressor corrosion, providing long-term reliability benefits.
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 process enhances the reliability of reactor devices, reduces plant shutdowns, and increases polymer production by minimizing the exposure of compressors to corrosive comonomers.
Implementation Method 1
at least a portion of a comonomer composition comprising at least a portion of the acid comonomer used in the polymerization, is compressed, to form a compressed comonomer composition, in the pressurization device, up to a discharge pressure ranging from 1000 Bar to 4000 Bar, and at a discharge temperature (DT) from 10° C. to 100° C.
Implementation Method 2
discharge temperature (DT) from 10° C. to 100° C.
Implementation Method 3
the reaction mixture is polymerized in the presence of at least one free-radical initiator, and at a pressure of at least 1000 Bar
Data Source
AI summary
A process to form an ethylene-based polymer comprising, in polymerized form, ethylene and at least one acid comonomer, said process comprising polymerizing a reaction mixture comprising the ethylene and the acid comonomer, in a reactor configuration comprising at least one Secondary compressor, at least one pressurization device, and at least one reactor selected from the following: at least one autoclave reactor, at least one tubular reactor, or a combination thereof; and wherein the reaction mixture is polymerized in the presence of at least one free-radical initiator, and at a pressure of at least 1000 Bar; and wherein at least a portion of a comonomer composition comprising at least a portion of the acid comonomer used in the polymerization, is compressed, to form a compressed comonomer composition, in the pressurization device, up to a discharge pressure ranging from 1000 Bar to 4000 Bar, and at a discharge temperature (DT) from 10 C to 100 C; and wherein the compressed comonomer composition bypasses the Secondary compressor, and is fed, downstream from the Secondary compressor, into the reactor, and/or into one or more feed streams to the reactor.