Liquid Activator Introduction in Olefin Polymerization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for introducing activators to olefin polymerization reactors are complex and costly, with ionic salt activators being insoluble in aliphatic hydrocarbons, leading to inaccuracies in measurement and handling, and requiring cumbersome systems for premixing with catalysts, which increases production costs and complexity.
Innovation Solution
The introduction of liquid activators mixed with aliphatic hydrocarbon solvents in a mixing vessel or inline mixer to form a solution, allowing for precise measurement and direct introduction to the reactor, reducing the need for large vessels and diluents, and minimizing aromatic solvent use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ionic salt activators are used in olefin polymerization, then effective catalyst activation is achieved, but insolubility in aliphatic hydrocarbons leads to measurement inaccuracies and handling difficulties
Solution Approach 1:
The patent introduces an intermediary substance (aromatic hydrocarbon solvent or complexing agent) that mediates between the ionic salt activator and the aliphatic hydrocarbon reaction medium. This intermediary enables the ionic activator to be delivered effectively to the catalyst while maintaining the desired aliphatic hydrocarbon environment for polymerization
Solution Approach 2:
The patent changes the physical state and solubility parameters of the activator by introducing aromatic hydrocarbon solvents or complexing agents. This transforms the activator from an insoluble ionic salt into a soluble complex or solution, enabling accurate measurement and handling while preserving catalytic activity
2Ease of operation
If ionic salt activators are dissolved in aromatic solvents to enable handling, then measurement and introduction become easier, but aromatic solvent removal adds significant cost and complexity to production
Solution Approach 1:
The patent employs a disposable pre-mixing approach where the activator is dissolved in a small amount of aromatic solvent or complexing agent in a separate pre-mixing step. This allows easy measurement and introduction of the activator without requiring continuous aromatic solvent presence in the polymerization reactor, thereby minimizing the need for complex devolatilization systems
Solution Approach 2:
The patent segments the activator introduction process into two distinct stages: (1) pre-mixing of activator with aromatic solvent or complexing agent in a separate vessel, and (2) introduction of this pre-mixed activator solution to the polymerization reactor. This segmentation allows easy handling in the first stage while minimizing aromatic solvent carryover to the second stage
3Ease of operation
If large vessels and large amounts of diluent are used for preparing catalyst and activator slurries, then mixing and handling become easier, but initial costs and devolatilization costs greatly increase
Solution Approach 1:
The patent applies partial action by using minimal amounts of aromatic solvent or complexing agent—just enough to dissolve or complex the activator for accurate measurement and introduction. This avoids the excessive use of large volumes of diluent that would be required for full slurry preparation, thereby reducing both initial costs and devolatilization costs while maintaining ease of operation
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 simplifies the introduction of activators, decreases capital and operating expenditures, and enhances the accuracy of activator measurement and handling, while reducing the cost and complexity of polyolefin production by using aliphatic solvents and minimizing aromatic hydrocarbon content.
Implementation Method 1
mixing an aliphatic hydrocarbon solvent with the liquid activator in the mixing vessel to form an activator solution
Data Source
AI summary
The present disclosure provides methods and systems for introducing an activator to a polymerization reactor. The methods may include introducing liquid activator to a mixing vessel or an inline mixer and mixing aliphatic hydrocarbon solvent to form an activator solution which is introduced to a polymerization reactor. The systems may include a storage vessel, a mixing vessel or inline mixer configured to mix a liquid activator with a hydrocarbon solvent, and a polymerization reactor. The present disclosure also provides a process for producing a polyolefin. The process may include introducing liquid activator to an inline mixer and mixing an aliphatic hydrocarbon solvent with the liquid activator to form an activator solution. The process may include introducing the activator solution, a catalyst, and an olefin feed to a polymerization reactor.