Upgrading Reactor Fouling Reduction Through Polymer Morphology
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Solution Overview
Problem
The formation of high molecular weight polymer by-products during ethylene tetramerization processes leads to reactor fouling, necessitating plant shut-downs and reducing the efficiency and yield of desired products like 1-octene and 1-hexene.
Innovation Solution
Oligomerizing C2 to C4 hydrocarbons in the presence of a fouling inhibitor with a particle size D50 of less than 100 microns, which changes the morphology of the polymer formed, reducing its propensity to foul the reactor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a Cr-based ethylene tetramerization catalyst is used to produce 1-octene, then the yield of desired product is improved, but high molecular weight polymer by-products are formed causing reactor fouling
Solution Approach 1:
A fouling inhibitor serves as an intermediary substance that interacts with the polymer by-products formed during tetramerization. The inhibitor changes the morphology of the polymer from a form that causes fouling to a form that remains in solution, thereby mediating between the desired polymerization reaction and the harmful fouling effect.
Solution Approach 2:
The patent changes physical parameters of the polymer by-products, specifically their morphology and particle size distribution. By controlling these parameters through the addition of a fouling inhibitor, the polymer remains dissolved in the reaction medium rather than precipitating and fouling the reactor.
2Productivity
If reaction temperature is increased to improve productivity, then the rate of tetramerization is improved, but selectivity shifts from 1-octene towards 1-hexene and polymer fouling increases
Solution Approach 1:
The fouling inhibitor acts as a mediator that allows the reaction to proceed at higher temperatures without the harmful effects of polymer precipitation and fouling. This enables the system to operate in a temperature range that favors 1-octene selectivity while maintaining productivity.
3Quantity of substance
If polymer precipitates out of solution in the reactor, then the polymer by-products are removed from the reaction medium, but reactor fouling occurs and plant run time is reduced
Solution Approach 1:
The patent changes the physical state parameters of the polymer by-products, specifically keeping them in the dissolved state rather than allowing precipitation. This parameter change maintains reactor cleanliness and operational continuity while still managing the polymer by-products effectively.
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 method effectively minimizes reactor fouling, increases the yield of linear alpha olefins, and reduces process downtime by altering the polymer morphology to prevent deposition on reactor surfaces.
Implementation Method 1
the fouling inhibitor changes the morphology of the polymer
Implementation Method 2
a Cr-based ethylene tetramerization catalyst
Implementation Method 3
oligomerizing C2 to C4 hydrocarbons... forming linear alpha olefins and polymer
Data Source
AI summary
A method for reducing fouling in an oligomerizing reactor that includes upgrading C2 to C4 hydrocarbons within the oligomerizing reactor in the presence of a fouling inhibitor having a particle size D50 of less than 100 μm and forming linear alpha olefins and polymer during the oligomerizing, wherein the fouling inhibitor changes the morphology of the polymer.