Hydrocyclone Catalyst Classification for Consistent Olefin Polymerization
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Solution Overview
Problem
Improper particle size features of catalyst system components in olefin-based polymerizations lead to operational difficulties and inconsistent polymer properties in loop slurry and fluidized bed reactors.
Innovation Solution
The use of hydrocyclones to modify the particle size distribution of catalyst system components by introducing a feed mixture containing a fluid and catalyst system component into an inlet, discharging specific solid streams, and spray drying the underflow stream to form a modified catalyst component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If catalyst system components with improper particle size features are used, then operational difficulties occur during polymerization, but using proper particle size control methods increases process complexity
Solution Approach 1:
The patent applies preliminary action by modifying the catalyst system component particle size distribution before the polymerization reaction occurs. The hydrocyclone classification process is performed in advance to remove fine particles (<20 μm) from the catalyst components, ensuring that only properly sized particles proceed to polymerization. This pre-treatment prevents operational difficulties during the actual polymerization process while maintaining a relatively simple overall process flow.
2Stability of the object's composition
If fine particles are removed from catalyst system components, then polymer homogeneity improves, but some catalyst material is lost in the overflow stream
Solution Approach 1:
The patent applies parameter changes by utilizing the hydrocyclone's ability to separate particles based on size parameters. By setting the classification cutoff at 20 μm, the process optimizes the balance between removing fine particles that cause polymerization issues and retaining sufficient catalyst material. The hydrocyclone operates by changing the flow parameters and particle concentration to achieve effective separation while minimizing material loss in the overflow stream.
3Manufacturing precision
If hydrocyclone classification is applied to modify particle size distribution, then polymer properties become more consistent, but additional equipment and process steps are required
Solution Approach 1:
The patent applies pneumatics and hydraulics by using a hydrocyclone, which is a hydraulic classification device that utilizes fluid dynamics to separate particles based on size. The hydrocyclone uses centrifugal forces generated by fluid flow to classify catalyst system components, removing fine particles without mechanical moving parts. This hydraulic approach achieves precise particle size control and consistent polymer properties while avoiding complex mechanical classification equipment.
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 method effectively reduces the amount of fine particles, improves polymer homogeneity, and enhances polymer properties by controlling the particle size distribution, resulting in more consistent polymer particle sizes and improved polymer properties.
Implementation Method 1
introducing a feed mixture containing a fluid and from 1 to 15 wt. % of a catalyst system component into an inlet of a hydrocyclone
Implementation Method 2
discharging from the hydrocyclone an overflow stream containing from 0.1 to 5 wt. % solids and an underflow stream containing from 10 to 40 wt. % solids
Implementation Method 3
spray drying the underflow stream to form a modified catalyst component
Data Source
AI summary
Methods for modifying a catalyst system component are disclosed in which a feed mixture containing a fluid and from 1 to 15 wt. % of a catalyst system component is introduced into an inlet of a hydrocyclone, an overflow stream containing from 0.1 to 5 wt. % solids and an underflow stream containing from 10 to 40 wt. % solids are discharged from the hydrocyclone, and the underflow stream is spray dried to form a modified catalyst component. Often, from 4 to 20 wt. % of the catalyst system component in the feed mixture has a particle size of less than or equal to 20 μm, or less than or equal to 10 μm.