Propylene Catalyst Feeding Without Heavy Hydrocarbon Carriers
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Solution Overview
Problem
Existing catalyst feeding methods for olefin bulk polymerization processes require additional steps to remove heavy hydrocarbons, leading to increased production costs and polymer contamination, and can cause obstructions and efficiency losses.
Innovation Solution
Mixing the catalyst with a polymerizable liquid to form a catalyst mixture free of C20 or greater hydrocarbons, and introducing this mixture into a polymerization reactor without inert carriers, allowing for direct activation and polymerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heavy hydrocarbon compounds (olefinic waxes, mineral oils) are used as catalyst carriers in bulk polymerization, then catalyst dosing becomes easier and storage stability improves, but additional processing steps are required to remove these compounds and they contaminate the final polymer
Solution Approach 1:
The invention extracts and eliminates the harmful heavy hydrocarbon compounds from the catalyst carrier system, replacing them with light hydrocarbon solvents (C1-C4) that do not contaminate the final polymer product, thereby removing the source of contamination while maintaining ease of catalyst dosing
Solution Approach 2:
The process discards the traditional heavy hydrocarbon carriers after they have served their purpose of facilitating catalyst dosing and storage, and instead uses volatile light hydrocarbons that can be easily removed or recovered without leaving residues in the final polymer
2Ease of operation
If inert liquid carriers are used to feed catalyst into bulk polymerization, then catalyst feeding becomes easier, but the concentration of both catalyst and monomer is diluted, decreasing catalyst activity and monomer conversion
Solution Approach 1:
The invention changes the key parameter of the carrier solvent from heavy hydrocarbons (high boiling point, high viscosity) to light hydrocarbons (low boiling point, low viscosity), which fundamentally alters the dilution effect and allows for easier catalyst feeding without significantly diluting the monomer concentration, thereby maintaining high catalyst activity and monomer conversion
3Ease of operation
If activated catalyst is fed into gas-phase reactor using inert gas or inert compounds, then catalyst can be carried to reactor bed, but obstructions occur at catalyst feed point as activated catalyst contacts monomer under uncontrolled conditions
Solution Approach 1:
The invention uses light hydrocarbon solvents as an intermediary carrier that can dissolve or disperse the activated catalyst, allowing for smooth transport into the gas-phase reactor without aggregation or obstruction at the feed point, while controlling the conditions of catalyst-monomer contact
4Ease of operation
If inert gas such as nitrogen is used to carry catalyst into bulk polymerization, then catalyst can be introduced into reactor, but cavitation occurs in circulation loops
Solution Approach 1:
The invention transitions from using gaseous inert carriers (nitrogen) that cause cavitation in hydraulic circulation loops to using liquid light hydrocarbon carriers that are compatible with the hydraulic system, eliminating cavitation while maintaining effective catalyst introduction into the bulk polymerization reactor
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
Produces polymers substantially free of heavy hydrocarbons, reducing processing steps and equipment issues, while maintaining catalyst activity and efficiency.
Implementation Method 1
performing a polymerization on the catalyst mixture in the polymerization reactor to produce polypropylene
Data Source
AI summary
Methods of adding a catalyst to a bulk polymerization process may include mixing the catalyst with propylene to form a catalyst mixture that is substantially free of any C20 or greater hydrocarbons, feeding the catalyst mixture into a polymerization reactor, activating the catalyst mixture; and performing a polymerization on the catalyst mixture in the polymerization reactor. Polymers may be formed by polymerization processes that are substantially free of any C20 or greater hydrocarbons.