Two-Phase Ethylene Feed for Higher Output in Dual Reactor Polymerization
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Solution Overview
Problem
Conventional ethylene-based polymerization processes are limited by high solvent usage, which restricts reactor polymer concentration and plant capacity due to the need for a single, liquid-phase feed, leading to suboptimal production rates.
Innovation Solution
A two-phase ethylene feed stream is introduced to the second reactor, comprising a vapor and liquid phase, with a specific solvent-to-ethylene ratio, to enhance polymer concentration and production rates in dual reactor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a single, liquid-phase feed stream is used to dissolve ethylene monomer in solvent, then consistent reactor feed is achieved, but reactor polymer concentration is limited and plant capacity is restricted
Solution Approach 1:
The invention changes the physical state parameter of the ethylene feed from single liquid-phase to two-phase (vapor-liquid) system. By introducing ethylene as a vapor phase component mixed with liquid solvent, the system achieves higher ethylene concentration in the reactor while maintaining feed consistency through controlled phase composition and ratio.
Solution Approach 2:
The invention utilizes phase transition by introducing ethylene monomer in vapor phase that mixes with liquid solvent to form a two-phase feed stream. This phase transition approach allows higher ethylene loading capacity compared to completely liquid-phase dissolution, thereby increasing polymer concentration and plant capacity.
2Stability of the object's composition
If high solvent usage is employed to dissolve ethylene monomer, then complete dissolution is achieved, but solvent load increases and production rate is suboptimal
Solution Approach 1:
The invention changes the dissolution parameter by transitioning from complete liquid-phase dissolution to a two-phase system where ethylene exists primarily in vapor phase with partial liquid-phase dissolution. This parameter change reduces the amount of solvent needed while maintaining adequate ethylene availability for polymerization, thereby reducing solvent load and improving production rate.
Solution Approach 2:
The invention extracts the ethylene monomer from complete liquid-phase dissolution and introduces it as a separate vapor phase component. This separation allows the system to achieve adequate ethylene concentration without requiring excessive solvent, thus reducing solvent load while maintaining production efficiency.
3Productivity
If reduced solvent usage is implemented, then plant capacity is boosted, but feed consistency may be compromised
Solution Approach 1:
The invention changes the composition parameters by defining specific ranges for vapor-phase ethylene concentration and liquid-phase solvent composition. By controlling these parameters within optimized ranges, the system achieves reduced solvent usage while maintaining feed consistency through balanced phase composition and stable operating conditions.
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 two-phase feed technology increases ethylene-based polymer production rates by up to 9.5% while maintaining solvent load within processing constraints, thereby improving plant capacity and efficiency.
Implementation Method 1
introducing the first reactor product and a two-phase second feed comprising ethylene monomer, hydrocarbon solvent, and optionally one or more C3-C12 alpha-olefin comonomer
Implementation Method 2
a two-phase ethylene feed stream is introduced to the second reactor, comprising a vapor and liquid phase
Data Source
AI summary
Embodiments of a dual reactor solution polymerization method comprising: introducing a first feed comprising ethylene monomer, optionally hydrogen, optionally C3-C12 alpha-olefin comonomer, and hydrocarbon solvent to a first polymerization reactor to produce via solution polymerization at a temperature from 100 to 225° C. a first reactor product comprising ethylene-based polymer; and introducing the first reactor product and a two-phase second feed comprising ethylene monomer, hydrocarbon solvent, optionally hydrogen, and optionally C3-C12 alpha-olefin comonomer to a second polymerization reactor to produce via solution polymerization ethylene-based polymer, wherein a ratio by weight of the summation of the hydrocarbon solvent plus comonomer to ethylene monomer in the two-phase second feed is from 0.1 to 2.2.