Pre-activation Vessel System for Catalyst Productivity
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Solution Overview
Problem
In the polymerization of 1-olefins, existing technologies face challenges in achieving high catalyst productivity and polymer morphology, leading to increased catalyst usage and residues in the polymeric product, which affects reactor operability and product purity.
Innovation Solution
A vessel system with a vertically arranged contacting vessel having a specific height-to-diameter ratio and a stirrer positioned between the inlet and outlet, used for pre-activating a solid catalyst component by feeding a mixture of the catalyst, an activating compound, and optional additives, resulting in a pre-activated catalyst for improved polymerization efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pre-activation of catalyst component is performed, then catalyst productivity is improved, but device complexity increases due to additional contacting vessel requirements
Solution Approach 1:
The patent combines the pre-activation function with the existing contacting vessel used for polymerization, eliminating the need for separate pre-activation equipment. The same vessel that contacts monomer and catalyst during polymerization is used to pre-activate the catalyst component by contacting it with activating compound, thereby achieving catalyst activation without adding device complexity.
Solution Approach 2:
The contacting vessel is designed to perform multiple functions: it serves as both the pre-activation vessel for catalyst activation and the polymerization reactor. This multi-functional design allows the system to achieve catalyst pre-activation while avoiding additional equipment, thus improving productivity without increasing device complexity.
2Quantity of substance
If catalyst usage is reduced to improve economy, then production cost decreases, but catalyst activity must be increased which complicates the activation process
Solution Approach 1:
The patent applies preliminary action by pre-activating the catalyst component before it enters the polymerization reactor. The catalyst component is contacted with activating compound in advance within the contacting vessel, ensuring high catalyst activity is achieved before polymerization begins. This allows reduced catalyst usage while maintaining high productivity, as the pre-activated catalyst requires smaller quantities to achieve the same production rate.
3Reliability
If polymer morphology is improved for better reactor operability, then fouling prevention increases, but process parameters must be optimized which increases operational complexity
Solution Approach 1:
The patent uses preliminary action to improve polymer morphology by pre-activating the catalyst component before polymerization. The pre-activated catalyst produces polymer with better morphology characteristics during the polymerization process, which prevents fouling in the reactor and improves operational reliability. The morphology improvement is achieved through the pre-activation step rather than complex process parameter optimization during 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
The vessel system enhances catalyst activity, reduces catalyst usage, improves polymer morphology, and prevents fouling in reactors, leading to higher catalyst mileage and increased polymer purity.
Implementation Method 1
a stirrer positioned within the contacting vessel, wherein the stirrer is located at a position in the contacting vessel between the inlet and the outlet
Implementation Method 2
pre-activating a solid catalyst component by feeding a mixture of the catalyst, an activating compound, and optional additives
Data Source
AI summary
An apparatus for polymerizing olefins including a polymerization reactor and a vessel system for pre-activating a solid catalyst component, wherein the vessel system is arranged upstream of the polymerization reactor. The vessel system includes a contacting vessel which includes a main portion, a base portion, a head portion, an inlet, an outlet, and a stirrer positioned within the contacting vessel, wherein the ratio (H/D) of the height (H) of the main portion to the diameter (D) of the main portion is 1.8 or greater. The stirrer is located at a position between the inlet and the outlet.