Continuity Additives Mitigate Fouling in Polymerization Reactors
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Solution Overview
Problem
Commercial polyolefin production reactors face disruptions due to sheeting and fouling issues, particularly with metallocene catalysts, which lead to reactor discontinuities and reduced catalyst productivity when using continuity additives.
Innovation Solution
Development of continuity additives that include a substance capable of reducing fouling, sheeting, and static levels in polymerization reactors, combined with a scavenger that neutralizes water, avoiding the use of polysulfone polymers, polymeric polyamines, or oil-soluble sulfonic acids, and adjusting the scavenger amount to minimize interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuity additives are added to reduce sheeting and fouling, then reactor operability is improved, but catalyst productivity is reduced
Solution Approach 1:
The patent modifies the chemical composition parameters of the continuity additive by incorporating specific scavengers (such as triethyl aluminum, trimethyl aluminum, or diethyl aluminum chloride) that neutralize water. This parameter change allows the additive to maintain effectiveness in reducing sheeting and fouling while minimizing the negative impact on catalyst productivity through optimized chemical composition.
Solution Approach 2:
The patent creates a composite continuity additive system combining the base substance (such as alkoxylated amines or carboxylic acid salts) with specific scavenger compounds. This composite approach allows the additive to simultaneously address multiple issues: reducing electrostatic activity for sheeting prevention, neutralizing water to protect catalyst activity, and maintaining overall reactor operability without excessive productivity loss.
2Productivity
If scavenger is added to neutralize water in continuity additive, then catalyst productivity is improved, but electrostatic activity levels may be affected
Solution Approach 1:
The patent carefully controls the amount and type of scavenger added to the continuity additive system. By optimizing the scavenger concentration and selecting specific compounds (such as triethyl aluminum versus trimethyl aluminum), the system achieves sufficient water neutralization to protect catalyst productivity while maintaining electrostatic activity levels within acceptable ranges to prevent sheeting.
Solution Approach 2:
The patent applies different functional properties to different components of the continuity additive system. The scavenger component specifically targets water neutralization to protect catalyst activity, while the base substance component (such as alkoxylated amines) specifically addresses electrostatic activity reduction. This division of functional responsibilities allows each component to optimize its specific function without interfering excessively with the other.
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
The continuity additives effectively mitigate reactor discontinuities and maintain electrostatic activity levels, improving reactor operability with minimal impact on catalyst productivity, as demonstrated by increased catalyst productivity and reduced sheeting events.
Implementation Method 1
a scavenger mixed with the substance, optionally, the scavenger neutralizing water coming in contact therewith
Implementation Method 2
a substance characterized by an ability to reduce at least one of fouling, sheeting, and static level of a material present in a polymerization reactor system
Data Source
AI summary
A continuity additive according to one general approach includes a substance having an ability to reduce, prevent, or mitigate at least one of fouling, sheeting, and static level of a material present in a polymerization reactor system when added to the reactor system in an effective amount, with the proviso that the substance is not a polysulfone polymer, a polymeric polyamine, or an oil-soluble sulfonic acid; and a scavenger contacted with the substance, optionally, the scavenger neutralizing water coming in contact therewith. Additional continuity additives, methods of making continuity additives, and use of continuity additives are also presented.