U.S. patent application number 13/682336 was filed with the patent office on 2014-05-22 for polyolefin production with multiple polymerization reactors.
This patent application is currently assigned to Chevron Phillips Chemical Company, LP. The applicant listed for this patent is Chevron Phillips Chemical Company, LP. Invention is credited to Elizabeth An Benham, Maruti Bhandarkar, Catherine M. Gill, Rebecca A. Gonzales, Scott E. Kufeld, Joel A. Mutchler, Thanh T. Nguyen, Timothy O. Odi.
Application Number | 20140140894 13/682336 |
Document ID | / |
Family ID | 49681215 |
Filed Date | 2014-05-22 |
United States Patent
Application |
20140140894 |
Kind Code |
A1 |
Bhandarkar; Maruti ; et
al. |
May 22, 2014 |
POLYOLEFIN PRODUCTION WITH MULTIPLE POLYMERIZATION REACTORS
Abstract
A polyolefin production system including: a first reactor
configured to produce a first discharge slurry having a first
polyolefin; a second reactor configured to produce a second
discharge slurry having a second polyolefin; and a post-reactor
treatment zone having at least a separation vessel configured to
receive the second discharge slurry or both the first discharge
slurry and the second discharge slurry.
Inventors: |
Bhandarkar; Maruti;
(Kingwood, TX) ; Benham; Elizabeth An; (Spring,
TX) ; Gonzales; Rebecca A.; (Houston, TX) ;
Kufeld; Scott E.; (Houston, TX) ; Mutchler; Joel
A.; (Kingwood, TX) ; Gill; Catherine M.;
(Kingwood, TX) ; Nguyen; Thanh T.; (Sugar Land,
TX) ; Odi; Timothy O.; (Kingwood, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Chevron Phillips Chemical Company, LP |
The Woodlands |
TX |
US |
|
|
Assignee: |
Chevron Phillips Chemical Company,
LP
The Woodlands
TX
|
Family ID: |
49681215 |
Appl. No.: |
13/682336 |
Filed: |
November 20, 2012 |
Current U.S.
Class: |
422/132 ;
422/129; 422/134 |
Current CPC
Class: |
B01J 19/2465 20130101;
B01J 19/1825 20130101; B01J 19/2455 20130101; C08F 2/001 20130101;
B01J 2219/24 20130101; B01J 19/245 20130101; C08F 2/01 20130101;
B01J 19/1837 20130101; B01J 19/1818 20130101; B01J 2219/00024
20130101; C08F 10/00 20130101; C08F 2/001 20130101 |
Class at
Publication: |
422/132 ;
422/134; 422/129 |
International
Class: |
B01J 19/24 20060101
B01J019/24 |
Claims
1. A polyolefin production system comprising: a first reactor
configured to produce a first reactor discharge comprising a first
polyolefin; a second reactor configured to produce a second reactor
discharge comprising a second polyolefin; and a post-reactor
treatment zone configured to receive the first reactor discharge
and the second reactor discharge, wherein the first and second
reactors are configured to allow the first reactor discharge to be
(a) transferred to the second reactor and, alternatively, (b)
diverted to by-pass the second reactor and fed into the
post-reactor treatment zone wherein to the first and second
polyolefins are first contacted in the post-reactor treatment
zone.
2. The polyolefin production system of claim 1, wherein the first
reactor and the second reactor each comprise a loop reactor.
3. The polyolefin production system of claim 1, wherein: the
post-reactor treatment zone comprises a separation vessel; and the
first and second polyolefins are transferred to the separation
vessel such that the first and second polyolefins are first
contacted in the separation vessel.
4. The polyolefin production system of claim 1, wherein: the
post-reactor treatment zone comprises a purge column; and the first
and second polyolefins are transferred to the purge column such
that the first and second polyolefins are first contacted in the
purge column.
5. The polyolefin production system of claim 1, wherein: the
post-reactor treatment zone comprises an extruder feed tank; and
the first and second polyolefins are transferred to the extruder
feed tank such that the first and second polyolefins are first
contacted in the extruder feed tank.
6. The polyolefin production system of claim 1, wherein: the
post-reactor treatment zone comprises an extruder; and the first
and second polyolefins are transferred to the extruder such that
the first and second polyolefins are first contacted at the inlet
of and blended in the extruder.
7. The polyolefin production system of claim 1, wherein the first
and second polyolefins are polyethylene.
8. The polyolefin production system of claim 1, wherein the first
polyolefin has a higher average molecular weight than the second
polyolefin.
9. The polyolefin production system of claim 1, wherein the second
polyolefin has a higher average molecular weight than the first
polyolefin.
10. The polyolefin production system of claim 1, wherein the first
polyolefin has a different density than the second polyolefin.
11. The polyolefin production system of claim 1, wherein the first
polyolefin is 30 weight % to 70 weight % of the second
polyolefin.
12. The polyolefin production system of claim 1, wherein the
post-reactor treatment zone comprises an extruder feed tank and an
extruder, and wherein performance additives are added into at least
one of the extruder feed tank or the extruder.
13. A polyolefin production system comprising: a first-reactor
configured to produce a first reactor discharge comprising
polyolefin and non-polyolefin components; and a post-reactor
treatment zone configured to receive the first reactor discharge
and produce a first extruded polyolefin and a second extruded
polyolefin.
14. The polyolefin production system of claim 13, wherein the
post-reactor treatment zone comprises a separation vessel
configured to receive the first reactor discharge and produce first
and second separation-vessel product streams.
15. The polyolefin production system of claim 13, wherein: the
post-reactor treatment zone comprises a separation vessel and a
purge column, wherein: the separation vessel is configured to
receive the first reactor discharge and produce a separation-vessel
product stream, and the purge column is configured to receive the
separation-vessel product stream and produce first and second
purge-column product streams.
16. The polyolefin production system of claim 13, wherein: the
post-reactor treatment zone comprises a separation vessel, a purge
column, and an extruder feed tank; the separation vessel is
configured to receive the first reactor discharge and produce a
separation-vessel product stream, the purge column is configured to
receive the separation-vessel product stream and produce a
purge-column product stream, and the extruder feed tank is
configured to receive the purge-column product stream and produce
first and second extruder-tank product streams.
17. The polyolefin production system of claim 13, further
comprising a second reactor configured to produce a second reactor
discharge which is fed into the first reactor.
18. The polyolefin production system of claim 17, wherein
polyolefin in the second reactor discharge has a higher average
molecular weight than polyolefin in the first reactor
discharge.
19. The polyolefin production system of claim 17, wherein
polyolefin the first reactor discharge has a higher average
molecular weight than polyolefin the second reactor discharge.
20. The polyolefin production system of claim 17, wherein
polyolefin in the second reactor discharge has a different density
than polyolefin in the first reactor discharge.
21. The polyolefin production system of claim 17, wherein
polyolefin in the second reactor discharge is 30 weight % to 70
weight % of polyolefin in the second reactor discharge.
22. The polyolefin production system of claim 13, wherein the first
extruded polyolefin and the second extruded polyolefin comprise
different additive packages.
23. The polyolefin production system of claim 13, wherein the
different additive packages comprise surface modifiers, UV
inhibitors, antioxidants, colorants, pigments, or any combination
thereof.
24. A polyolefin production system comprising: a first reactor
configured to produce a first discharge slurry comprising a first
polyolefin; a second reactor configured to produce a second
discharge slurry comprising a second polyolefin; and a post-reactor
treatment zone comprising a separation vessel configured to receive
as separate feeds the first discharge slurry and the second
discharge slurry.
25. The polyolefin production system of claim 24, wherein the first
and second reactors are configured to allow the first discharge
slurry to be (a) transferred to the second reactor and,
alternatively, (b) diverted to by-pass the second reactor and fed
into the post-reactor treatment zone.
26. The polyolefin production system of claim 24, wherein the first
discharge slurry and the second discharge slurry initially meet in
the separation vessel.
27. The polyolefin production system of claim 24, wherein the first
discharge slurry and the second discharge slurry do not meet
upstream of the separation vessel.
28. The polyolefin production system of claim 24, wherein the first
discharge slurry and the second discharge slurry do not initially
meet in a conduit.
29. The polyolefin production system of claim 24, wherein the first
and second polyolefins are transferred to the separation vessel
such that the first and second polyolefins initially meet in the
separation vessel.
30. The polyolefin production system of claim 24, wherein: the
post-reactor treatment zone comprises a purge column; and the first
and second polyolefins are transferred to the purge column such
that the first and second polyolefins initially meet in inlet
piping of the purge column or in the purge column.
31. The polyolefin production system of claim 24, wherein: the
post-reactor treatment zone comprises an extruder feed tank; and
the first and second polyolefins are transferred to the extruder
feed tank such that the first and second polyolefins initially meet
in inlet piping of the extruder feed tank or in the extruder feed
tank.
32. The polyolefin production system of claim 24, wherein: the
post-reactor treatment zone comprises an extruder; and the first
and second polyolefins are transferred to the extruder such that
the first and second polyolefins initially meet in inlet piping of
the extruder or in the extruder, and are blended in the
extruder.
33. The polyolefin production system of claim 24, wherein the first
polyolefin has a higher average molecular weight than the second
polyolefin.
34. The polyolefin production system of claim 24, wherein the
second polyolefin has a higher average molecular weight than the
first polyolefin.
35. The polyolefin production system of claim 24, wherein the first
polyolefin has a different density than the second polyolefin.
36. The polyolefin production system of claim 24, wherein the first
polyolefin is 30 weight % to 70 weight % of the second polyolefin.
Description
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates generally to polyolefin
production and, more specifically, to coupling and decoupling of
polymerization reactors and downstream processing in a polyolefin
production system.
[0003] 2. Description of the Related Art
[0004] This section is intended to introduce the reader to aspects
of art that may be related to aspects of the present invention,
which are described and/or claimed below. This discussion is
believed to be helpful in providing the reader with background
information to facilitate a better understanding of the various
aspects of the present invention. Accordingly, it should be
understood that these statements are to be read in this light, and
not as admissions of prior art.
[0005] As chemical and petrochemical technologies have advanced,
the products of these technologies have become increasingly
prevalent in society. In particular, as techniques for bonding
simple molecular building blocks into longer chains (or polymers)
have advanced, the polymer products, typically in the form of
various plastics, have been increasingly incorporated into everyday
items. Polyolefin polymers such as polyethylene, polypropylene, and
their copolymers, are used for piping, retail and pharmaceutical
packaging, food and beverage packaging, plastic bags, toys,
carpeting, various industrial products, automobile components,
appliances and other household items, and so forth.
[0006] Specific types of polyolefins, such as high-density
polyethylene (HDPE), have particular applications in the
manufacture of blow-molded and injection-molded goods, such as food
and beverage containers, film, and plastic pipe. Other types of
polyolefins, such as low-density polyethylene (LDPE), linear
low-density polyethylene (LLDPE), isotactic polypropylene (iPP),
and syndiotactic polypropylene (sPP) are also suited for similar
applications. The mechanical requirements of the application, such
as tensile strength and density, and/or the chemical requirements,
such thermal stability, molecular weight, and chemical reactivity,
typically determine what type of polyolefin is suitable.
[0007] One benefit of polyolefin construction, as may be deduced
from the list of uses above, is that it is generally non-reactive
with goods or products with which it is in contact.
[0008] This allows polyolefin products to be used in residential,
commercial, and industrial contexts, including food and beverage
storage and transportation, consumer electronics, agriculture,
shipping, and vehicular construction. The wide variety of
residential, commercial and industrial uses for polyolefins has
translated into a substantial demand for raw polyolefin which can
be extruded, injected, blown or otherwise formed into a final
consumable product or component.
[0009] To satisfy this demand, various processes exist by which
olefins may be polymerized to form polyolefins. These processes may
be performed at or near petrochemical facilities, which provide
ready access to the short-chain olefin molecules (monomers and
comonomers), such as ethylene, propylene, butene, pentene, hexene,
octene, decene, and other building blocks of the much longer
polyolefin polymers. These monomers and comonomers may be
polymerized in a liquid-phase polymerization reactor and/or
gas-phase polymerization reactor. As polymer chains develop during
polymerization in the reactor, solid particles known as "fluff" or
"flake" or "powder" are produced in the reactor.
[0010] The fluff may possess one or more melt, physical,
rheological, and/or mechanical properties of interest, such as
density, melt index (MI), melt flow rate (MFR), comonomer content,
molecular weight, crystallinity, and so on. Different properties
for the fluff may be desirable depending on the application to
which the polyolefin fluff or subsequently pelletized polylefin is
to be applied. Selection and control of the reaction conditions
within the reactor, such as temperature, pressure, chemical
concentrations, polymer production rate, catalyst type, and so
forth, may affect the fluff properties.
[0011] In addition to the one or more olefin monomers, a catalyst
(e.g., Ziegler-Natta, metallocene, chromium-based, etc.) for
facilitating the polymerization of the monomers may be added to the
reactor. For example, the catalyst may be a particle added via a
reactor feed stream and, once added, suspended in the fluid medium
within the reactor. Unlike the monomers, catalysts are generally
not consumed in the polymerization reaction. Moreover, an inert
hydrocarbon, such as isobutane, propane, n-pentane, i-pentane,
neopentane, and/or n-hexane, may be added to the reactor and
utilized as a diluent to carry the contents of the reactor.
However, some polymerization processes may not employ a separate
diluent, such as in the case of selected examples of polypropylene
production where the propylene monomer itself acts as the diluent.
In general, the diluent may facilitate circulation of the polymer
slurry in the reactor, heat removal from the polymer slurry in the
reactor, and so on.
[0012] The slurry discharge of the reactor typically includes the
polymer fluff as well as non-polymer components such as unreacted
olefin monomer (and comonomer), diluent, and so forth. This
discharge stream is generally processed, such as by a
diluent/monomer recovery system (e.g. flash vessel or separator
vessel, purge column, etc.) to separate the non-polymer components
from the polymer fluff. The recovered diluent, unreacted monomer,
and other non-polymer components from the recovery system may be
treated and recycled to the reactor, for example. As for the
recovered polymer (solids), the polymer may be treated to
deactivate residual catalyst, remove entrained or dissolved
hydrocarbons, dry the polymer, and pelletize the polymer in an
extruder, and so forth, before the polymer is sent to customer.
[0013] In some circumstances, to increase capacity of a polyolefin
polymerization line or to achieve certain desired polymer
characteristics, more than one polymerization reactor may be
employed, with each reactor having its own set of conditions. For
example, the respective reactor conditions including the
polymerization recipe can be set and maintained such that the
polyolefin (e.g., polyethylene, polypropylene) polymer product is
monomodal, bimodal, or multimodal. In the case of bimodal or
multimodal polymers, at least two polyolefin polymers (e.g., two
polyethylene polymers or two polypropylene polymers), each having a
different molecular weight fraction (and different density), for
instance, may be combined into one polymer product. The reactors
may be connected in series, such that the slurry from one reactor
may be transferred to a subsequent reactor, and so forth, until a
polyolefin polymer is produced discharging from the final reactor
with the desired set of characteristics. For example, a bimodal
polymer may be produced by two reactors in series, a trimodal
polymer may need three, and so on. Further, the amount of
polyolefin polymer produced in each reactor may be different, and
thus contribute a different weight percentage to the polymer
product.
[0014] The competitive business of polyolefin production drives
manufacturers in the continuous improvement of their processes in
order to lower production costs, improve product quality, increase
operating flexibility and capability, expand product slate variety,
expand product end-use and performance, and so on. In an industry
where billions of pounds of polyolefins are produced per year,
small incremental improvements, such as in product quality and
variety can result in significant economic benefit, increased
sales, larger market share, greater net-back, and so forth.
SUMMARY OF THE INVENTION
[0015] An aspect of the invention relates to a polyolefin
production system including: a first reactor configured to produce
a first reactor discharge comprising a first polyolefin; a second
reactor configured to produce a second reactor discharge having a
second polyolefin; and a post-reactor treatment zone configured to
receive the first reactor discharge and the second reactor
discharge, wherein the first and second reactors are configured to
allow the first reactor discharge to be (a) transferred to the
second reactor and, alternatively, (b) diverted to by-pass the
second reactor and fed into the post-reactor treatment zone wherein
the first and second polyolefins are first contacted in the
post-reactor treatment zone.
[0016] Another aspect of the invention relates to a polyolefin
production system including: a first-reactor configured to produce
a first reactor discharge comprising polyolefin and non-polyolefin
components; and a post-reactor treatment zone configured to receive
the first reactor discharge and produce a first extruded polyolefin
and a second extruded polyolefin.
[0017] Yet another aspect of the invention relates to a polyolefin
production system including: a first reactor configured to produce
a first discharge slurry having a first polyolefin; a second
reactor configured to produce a second discharge slurry comprising
a second polyolefin; and a post-reactor treatment zone comprising a
separation vessel configured to receive as separate feeds the first
discharge slurry and the second discharge slurry.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Advantages of the invention may become apparent upon reading
the following detailed description and upon reference to the
drawings in which:
[0019] FIG. 1 is a block flow diagram depicting an exemplary
polyolefin production system for producing polyolefin in accordance
with embodiments of the present techniques;
[0020] FIG. 2 is a process flow diagram of an exemplary reactor
system of the polyolefin production system of FIG. 1 in accordance
with embodiments of the present techniques;
[0021] FIGS. 3A-5C are process flow diagrams of exemplary reactor
systems applicable the polyolefin production system of FIG. 1 in
accordance with embodiments of the present techniques;
[0022] FIGS. 6A-6C are process flow diagrams of portions of
exemplary adjacent polyolefin production systems in accordance with
embodiments of the present techniques;
[0023] FIG. 7 is a process flow diagram of a loop reactor
discharging to two diluent/monomer recovery systems in accordance
with embodiments of the present techniques;
[0024] FIG. 8 is a process flow diagram of an exemplary reactor
system of the polyolefin production system of FIG. 1 in accordance
with embodiments of the present techniques;
[0025] FIGS. 9-11 are process flow diagrams of exemplary
diluent/monomer recovery systems applicable in the polyolefin
production system of FIG. 1 in accordance with embodiments of the
present techniques;
[0026] FIG. 12 is a process flow diagram of two adjacent exemplary
monomer/diluent recovery systems in accordance with embodiments of
the present techniques;
[0027] FIG. 13 is a process flow diagram depicting an exemplary
separation vessel in a diluent/monomer recovery system as capable
to receive two fluff product slurries from one or more reactor
systems in accordance with embodiments of the present
techniques;
[0028] FIG. 14 is a process flow diagram of an exemplary extrusion
system and loadout system of the polyolefin production system of
FIG. 1 in accordance with embodiments of the present techniques;
and
[0029] FIGS. 15A-15C are process flow diagrams of exemplary
alternatives for the extrusion system of FIGS. 1 and 14 in
accordance with embodiments of the present techniques.
DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS
[0030] One or more specific embodiments of the present invention
will be described below. To provide a concise description of these
embodiments, not all features of an actual implementation are
described in the specification. It should be appreciated that in
the development of any such actual implementation, as in any
engineering or design project, numerous implementation-specific
decisions must be made to achieve the developers' specific goals,
such as compliance with system-related and business-related
constraints, which may vary from one implementation to another.
Moreover, it should be appreciated that such a development effort
might be complex and time consuming, but would nevertheless be a
routine undertaking of design, fabrication, and manufacture for
those of ordinary skill in the art and having the benefit of this
disclosure.
[0031] Embodiments of the present techniques relate to uniquely
increasing operating flexibility and polyolefin product slate
capability. The polyolefin production system is configured with the
capability to operate polymerization reactors in both series and
parallel.
[0032] The series mode may be characterized as a coupled operation
of the polymerization reactors in certain examples. The parallel
mode may be characterized as a decoupled or independent operation
of the polymerization reactors in examples. This capability to
shift operation of a set of polymerization reactors between series
operation and parallel operation may provide for flexibility in
producing monomodal and multimodal (e.g., bimodal) polyolefin
polymers, and also provide shutdown and maintenance flexibility, as
discussed below.
[0033] Thus, embodiments of the present techniques relate to
process improvements for a polyolefin plant to give product type
flexibility. In certain embodiments, at least two slurry loop
reactors are run in series and then decoupled to run in parallel or
decoupled with one reactor run while the other reactor is down for
maintenance. This gives the plant flexibility to run bimodal
products and switch to single reactor products for varying markets
conditions. The parallel reactors could run on separate parallel
lines or combined after the reactor discharge streams.
[0034] The post-reactor treatment zone in the polyolefin production
system may be configured with the capability to receive: (1)
product polyolefin slurries discharged from polymerization reactors
operating in parallel mode; and also (2) the product polyolefin
slurry from the terminal or final reactor in a set of
polymerization reactors operating in series mode. The post-reactor
treatment zone may contact, combine, and blend any plurality of
product polyolefin slurries received. In other words, in cases of
the post-reactor treatment zone receiving more than one product
polyolefin slurry, the product polyolefin slurries may meet or come
into contact and combine in the post-reactor treatment zone, and me
blended in an extruder (e.g., in the flowing melt in the extruder)
of the post-reactor treatment zone, for example.
[0035] In addition to combining polyolefin slurries, the increased
operating and product flexibility in the polyolefin production
system may involve splitting, dividing, and diverting polyolefin
slurry and/or polyolefin solids streams. For example, the
polyolefin product slurry discharged from a polymerization reactor
may be diverted or split into two streams. In other examples,
polyolefin solids streams in the post-reactor treatment zone may be
diverted or split into two streams.
[0036] As discussed below, the post-reactor treatment zone may
include a monomer/diluent recovery system that removes hydrocarbons
from the polyolefins product slurry discharged from the
polymerization reactor(s), and an extrusion system that pelletizes
the treated polyolefin product from the monomer/diluent recovery
system. Moreover, the post-reactor treatment zone may include a
fractionation system that purifies the hydrocarbon (e.g., diluent,
monomer) recovered in the monomer/diluent recovery system.
[0037] Again, the present techniques provide flexibility. Reactors
can be run in series to produce bimodal or monomodal resins.
Reactors can be run in parallel and produce the same or different
products. The reactor produce can be blended, separated, sold as
fluff or pellets. Series reactor designs are sometimes limited in
the ability to produce a wide range of products. This could be
important with large plant capacities since a market might not be
able to take primarily bimodal types. Decoupling the reactors might
also give the plant flexibility to produce higher margin products
and greater throughput. This could improve plant economics.
[0038] In certain embodiments, a polyolefin plant can run in series
mode with at least two loop slurry reactors, and with the following
configurations and operational flexibility: (1) the production from
the downstream reactor feeds one separation operation (cyclone,
flash tank, etc.); (2) the production from the downstream reactor
is split and feeds parallel lines (cyclone, flash tank, purge
column, extruder, etc.); and (3) the production from the downstream
reactor is split at the extruder and the two parallel extruders run
at different conditions (additives, crosslinking) or similar
conditions.
[0039] Moreover, embodiments provide that the series reactors can
be operationally decoupled and run in parallel (or decouple and one
of the reactors is shut down for maintenance): (1) the production
from parallel reactors is combined downstream in the separations
(flash) operation, the purge column, or extruder; or (2) the
production from the parallel reactors is sent to parallel lines
(cyclone, flash vessel, purge column, extruder, etc.). Further, the
parallel reactors may be switched to series operation, and the
reactors combined by a continuous transfer of slurry from the one
reactor to the other reactor.
[0040] In addition, the present techniques may be beneficial in
operating adjacent polyolefin production lines. In some examples,
the present techniques may provide for retrofit of an existing
installation. For instance, existing adjacent polyolefin lines each
having a single polymerization (loop) reactor may be retrofitted to
provide for the present flexibility to operate two reactors in
parallel and series modes, and thus to facilitating ease of
monomodal and bimodal production, for example. Lastly, while not
depicted in the figures, a fluff slurry processing system may be
disposed between two reactors in series. In certain examples, the
fluff slurry processing system removes light components from the
transfer slurry discharging from the first reactor to the second
reactor.
I. Polyolefin Production Overview
[0041] Turning now to the drawings, and referring initially to FIG.
1, a block diagram depicts an exemplary production system 10 for
producing polyolefin such as polyethylene, polypropylene, and their
copolymers, etc. The exemplary production system 10 is typically a
continuous operation but may include both continuous and batch
systems. An exemplary nominal capacity for the exemplary production
system 10 is about 700-1600 million pounds of polyolefin produced
per year. Exemplary hourly design rates are approximately 70,000 to
200,000 pounds of polymerized/extruded polyolefin per hour. It
should be emphasized, however, that the present techniques apply to
polyolefin manufacturing processes including polyethylene
production systems having nominal capacities and design rates
outside of these exemplary ranges.
[0042] Various suppliers 12 may provide reactor feedstocks 14 to
the production system 10 via pipelines, ships, trucks, cylinders,
drums, and so forth. The suppliers 12 may include off-site and/or
on-site facilities, including olefin plants, refineries, catalyst
plants, and the like. Examples of possible feedstocks include
olefin monomers and comonomers (such as ethylene, propylene,
butene, hexene, octene, and decene), diluents (such as propane,
isobutane, n-butane, n-hexane, and n-heptane), chain transfer
agents (such as hydrogen), catalysts (such as Ziegler-Natta
catalysts, chromium catalysts, and metallocene catalysts) which may
be heterogeneous, homogenous, supported, unsupported, and
co-catalysts such as, triethylboron, organoaluminum compounds,
methyl aluminoxane, triethylaluminum, borates, triisobutylaluminum,
etc., and activators such as solid super acids, and other
additives. In the case of ethylene monomer, exemplary ethylene
feedstock may be supplied via pipeline at approximately 800-1450
pounds per square inch gauge (psig) at 45-65.degree. F. Exemplary
hydrogen feedstock may also be supplied via pipeline, but at
approximately 900-1000 psig at 90-110.degree. F. Of course, a
variety of supply conditions may exist for ethylene, hydrogen, and
other feedstocks 14.
[0043] The suppliers 12 typically provide feedstocks 14 to a
reactor feed system 16, where the feedstocks 14 may be stored, such
as in monomer storage and feed tanks, diluent vessels, catalyst
tanks, co-catalyst cylinders and tanks, and so forth. In the case
of ethylene monomer feed, the ethylene may be fed to the
polymerization reactors without intermediate storage in the feed
system 16 in certain embodiments. In the feed system 16, the
feedstocks 14 may be treated or processed prior to their
introduction as feed 18 into the polymerization reactor system. For
example, feedstocks 14, such as monomer, comonomer, and diluent,
may be sent through treatment beds (e.g., molecular sieve beds,
aluminum packing, etc.) to remove catalyst poisons. Such catalyst
poisons may include, for example, water, oxygen, carbon monoxide,
carbon dioxide, and organic compounds containing sulfur, oxygen, or
halogens. The olefin monomer and comonomers may be liquid, gaseous,
or a supercritical fluid, depending on the type of reactor being
fed. Also, it should be noted that typically only a relatively
small amount of fresh make-up diluent as feedstock 14 is utilized,
with a majority of the diluent fed to the polymerization reactor
recovered from the reactor effluent.
[0044] The feed system 16 may prepare or condition other feedstocks
14, such as catalysts, for addition to the polymerization reactors.
For example, a catalyst may be prepared and then mixed with diluent
(e.g., isobutane or hexane) or mineral oil in catalyst preparation
tanks. Further, the feed system 16 typically provides for metering
and controlling the addition rate of the feedstocks 14 into the
polymerization reactor to maintain the desired reactor stability
and/or to achieve the desired polyolefin properties or production
rate. Furthermore, in operation, the feed system 16 may also store,
treat, and meter recovered reactor effluent for recycle to the
reactor. Indeed, operations in the feed system 16 generally receive
both feedstock 14 and recovered reactor effluent streams.
[0045] In total, the feedstocks 14 and recovered reactor effluent
are processed in the feed system 16 and fed as feed streams 18
(e.g., streams of monomer, comonomer, diluent, catalysts,
co-catalysts, hydrogen, additives, or combinations thereof) to the
reactor system 20. As discussed below, the streams 18 may be
delivered in feed conduits to the reactor which tap into the wall
of the polymerization reactor in the reactor system 20. Moreover, a
given feed system 16 may be dedicated to a particular reactor or to
multiple reactors disposed/operated in series or parallel. Further,
a feed system 16 may receive recycle components (e.g., diluent)
from one or more downstream processing systems.
[0046] The reactor system 20 may have one or more reactor vessels,
such as liquid-phase or gas-phase reactors. If multiple reactors
are employed, the reactors may be arranged in series, in parallel,
or in other combinations or configurations. As discussed below,
multiple reactors arranged and operated in series may be shifted in
operation to a parallel or independent operation.
[0047] In the polymerization reactor vessels, one or more olefin
monomers and optionally comonomers are polymerized to form a
product polymer particulates, typically called fluff or granules.
In one example, the monomer is ethylene and the comonomer is
1-hexene. In another example, the monomer is propylene and the
comonomer is ethylene. The fluff may possess one or more melt,
physical, rheological, and/or mechanical properties of interest,
such as density, melt index (MI), molecular weight, copolymer or
comonomer content, modulus, and the like. The reaction conditions,
such as temperature, pressure, flow rate, mechanical agitation,
product takeoff, component concentrations, catalyst type, polymer
production rate, and so forth, may be selected to achieve the
desired fluff properties.
[0048] In addition to the one or more olefin monomers and
comonomers, a catalyst that facilitates polymerization of the
ethylene monomer is typically added to the reactor. The catalyst
may be a particle suspended in the fluid medium within the reactor.
In general, Ziegler catalysts, Ziegler-Natta catalysts, metallocene
catalysts, chromium catalysts, and other well-known polyolefin
catalysts, as well as co-catalysts, may be used. Typically, an
olefin-free diluent or mineral oil, for example, is used in the
preparation and/or delivery of the catalyst in a feed conduit that
taps into the wall of the polymerization reactor. Further, diluent
may be fed into the reactor, typically a liquid-phase reactor.
[0049] The diluent may be an inert hydrocarbon that is liquid at
reaction conditions, such as isobutane, propane, n-butane,
n-pentane, i-pentane, neopentane, n-hexane, cyclohexane,
cyclopentane, methylcyclopentane, ethylcyclohexane, and the like.
The purpose of the diluent is generally to suspend the catalyst
particles and polymer within the reactor. Diluent, as indicated,
may also be used for reactor or line flushes to mitigate plugging
or fouling, to facilitate flow of the polymer slurry in lines, and
so on. Moreover, in examples of polypropylene production, the
propylene monomer itself may act as a diluent.
[0050] A motive device may be present within each of the one or
more reactors in the reactor system 20. For example, within a
liquid-phase reactor, such as a loop slurry reactor, an impeller
may create a mixing zone within the fluid medium. The impeller may
be driven by a motor to propel the fluid medium as well as any
catalyst, polyolefin fluff, or other solid particulates suspended
within the fluid medium, through the closed loop of the reactor.
Similarly, within a gas-phase reactor, such as a fluidized bed
reactor or plug flow reactor, one or more paddles or stirrers may
be used to mix the solid particles within the reactor.
[0051] The discharge of polyolefin fluff product slurry 22 of the
reactors from system 20 may include the polymer polyolefin fluff as
well as non-polymer components, such as diluent, unreacted
monomer/comonomer, and residual catalyst. In construction of the
reactors in certain embodiments, a discharge nozzle and conduit may
be installed (e.g., welded) at a tap or hole cut into the reactor
wall. The discharge of the fluff product slurry 22 exiting the
reactor (e.g., the final reactor in a series of reactors) through
the discharge nozzle may be subsequently processed, such as by a
diluent/monomer recovery system 24. The fluff product slurry 22 may
also be called a reactor product discharge slurry, a reactor
product discharge, or a reactor discharge, etc. Thus, depending on
context, a "reactor discharge" may refer to the fluff slurry
exiting the reactor and/or to the physical configuration (e.g.,
reactor wall tap or opening, nozzle, conduit, valve if any, etc.)
discharging the fluff slurry.
[0052] Furthermore, it should be noted that the liquid (e.g.,
diluent) in fluff product slurry 22 generally partially or fully
vaporizes through a flash line including a flash line heater (not
shown) downstream of the reactor in route to the diluent/monomer
recovery system 24. As discussed below, such vaporization may be
due to decreasing pressure through the flash line, and due to heat
added by the flash line heater (e.g., a conduit with a steam or
steam condensate jacket). In other words, in embodiments the flash
line and its heater are configured to volatize diluent, and to
increase enthalpy of the fluff product slurry 22. Moreover, the
flash line and flash line heater may be defined as: (1) part of the
reactor system; (2) disposed between the reactor system and the
diluent/monomer recovery system 24; or (3) part of the
diluent/monomer recovery system 24. In certain embodiments, the
flash line heater is defined as intermediate (disposed between) the
reactor system 20 and the diluent/monomer recovery system 24, and
with the post-reactor treatment zone not including the flash line
and flash line heater but beginning with the first vessel in the
recovery system 24
[0053] Nevertheless, the diluent/monomer recovery system 24 may
process the fluff product slurry 22 (whether the liquid in the
slurry 22 is partially or fully vaporized in the flash line) from
the reactor system 20 to separate non-polymer components 26 (e.g.,
diluent and unreacted monomer) from the polymer fluff 28. Moreover,
as also discussed below, a diluent/monomer recovery system 24 may
receive a fluff product slurry discharge 22 from one or more
reactors in the reactor system 20.
[0054] A fractionation system 30 may process the untreated
recovered non-polymer components 26 (e.g., diluentimonomer) to
remove undesirable heavy and light components and to produce
olefin-free diluent, for example. Fractionated product streams 32
may then return to the reactor system 20 either directly (not
shown) or via the feed system 16. Such olefin-free diluent may be
employed in catalyst preparation/delivery in the feed system 16 and
as reactor or line flushes in the reactor system 20.
[0055] A portion or all of the non-polymer components 26 may bypass
the fractionation system 30 and more directly recycle to the
reactor system (not shown) or the feed system 16, as indicated by
reference numeral 34. In certain embodiments, up to 80-95% of the
diluent discharged from the reactor system 20 bypasses the
fractionation system 30 in route to the polymerization feed system
16 (and ultimately the reactor system 20). Moreover, although not
illustrated, polymer granules intermediate in the recovery system
24 and typically containing active residual catalyst may be
returned to the reactor system 20 for further polymerization, such
as in a different type of reactor or under different reaction
conditions.
[0056] The polyolefin fluff 28 discharging from the diluent/monomer
recovery system 24 may be extruded into polyolefin pellets 38 in an
extrusion system 36. In the extrusion system 36, the fluff 28 is
typically extruded to produce polymer pellets 38 with the desired
mechanical, physical, and melt characteristics. An
extruder/pelletizer receives the extruder feed including one or
more fluff products 28 and whatever additives have been added.
Extruder feed may include additives added to the fluff products 28
to impart desired characteristics to the extruded polymer pellets
38. The extruder/pelletizer heats and melts the extruder feed which
then may be extruded (e.g. via a twin screw extruder) through a
pelletizer die under pressure to form polyolefin pellets 38. Such
pellets are typically cooled in a water system disposed at or near
the discharge of the pelletizer.
[0057] Additives added to the extruder feed (e.g., added at the
inlet piping or inlet equipment of the extruder) or added at the
extruder (e.g., injected into the melt channel of the extruder) may
include surface modifiers (e.g., slip agents, antiblocks,
tackifers), UV inhibitors, antioxidants (e.g., phenolics,
phosphites, thioesters, amines, etc.), colorants, pigments,
processing aids (e.g., flow promoters such as waxes & oils and
fluoroelastomers), peroxides, and other additives. The different
additives may be combined into an additive package for addition, as
appreciated by the skilled artisan. Furthermore, as may be deduced
from the variety of additives listed above and as discussed below
with respect to FIGS. 14-15C in accordance with the present
techniques, it may be beneficial to combine or divert incoming
parallel fluff 28 feeds from upstream recovery system(s) 24 and
match different additive packages with the fluff feeds, such as via
one or more extruder feed tanks and extruders.
[0058] Nevertheless, one or more loadout systems 39 may prepare the
polyolefin pellets 38 for shipment in to customers 40. In general,
the polyolefin pellets 38 may be transported from the extrusion
system 36 to a product loadout area 39 where the pellets 38 may be
stored, blended with other pellets, and/or loaded into railcars,
trucks, bags, and so forth, for distribution to customers 40.
Polyolefin pellets 38 shipped to customers 40 may include low
density polyethylene (LDPE), linear low density polyethylene
(LLDPE), medium density polyethylene (MDPE), high density
polyethylene (HDPE), enhanced polyethylene, isotactic polypropylene
(iPP), syndiotactic polypropylene (sPP), including various
copolymers, and so on. The polymerization and diluent recovery
portions of the polyolefin production system 10 may be called the
"wet" end 42 or alternatively "reaction" side of the process 10.
The extrusion 36 and loadout 39 systems of the polyolefin
production system 10 may be called the "dry" end 44 or
alternatively "finishing" side of the polyolefin process 10.
Moreover, while the polyolefin pellets 38 discharging from the
extrusion system 36 may be stored and blended in the loadout area
39, the polyolefin pellets 38 are generally not altered by the
loadout system 39 prior to being sent to the customer 40.
[0059] Polyolefin pellets 38 may be used in the manufacturing of a
variety of products, components, household items and other items,
including adhesives (e.g., hot-melt adhesive applications),
electrical wire and cable, agricultural films, shrink film, stretch
film, food packaging films, flexible food packaging, milk
containers, frozen-food packaging, trash and can liners, grocery
bags, heavy-duty sacks, plastic bottles, safety equipment,
carpeting, coatings, toys and an array of containers and plastic
products. To form the end-products or components, the pellets 38
are generally subjected to processing, such as blow molding,
injection molding, rotational molding, blown film, cast film,
extrusion (e.g., sheet extrusion, pipe and corrugated extrusion,
coating/lamination extrusion, etc.), and so on. Ultimately, the
products and components formed from polyolefin pellets 38 may be
further processed and assembled for distribution and sale to the
consumer. For example, extruded pipe or film may be packaged for
distribution to the customer, or a fuel tank comprising
polyethylene may be assembled into an automobile for distribution
and sale to the consumer, and so on.
[0060] Process variables in the polyolefin production system 10 may
be controlled automatically and/or manually via valve
configurations, control systems, and so on. In general, a control
system, such as a processor-based system, may facilitate management
of a range of operations in the polyolefin production system 10,
such as those represented in FIG. 1. Polyolefin manufacturing
facilities may include a central control room or location, as well
as a central control system, such as a distributed control system
(DCS) and/or programmable logic controller (PIC). Of course, the
reactor system 20 typically employs a processor-based system, such
as a DCS, and may also employ advanced process control known in the
art. The feed system 16, diluent/monomer recovery 24, and
fractionation system 30 may also be controlled by the DCS. In the
dry end of the plant, the extruder and/or pellet loading operations
may also be controlled via a processor-based system (e.g., DCS or
PLC). Moreover, in the controls systems, computer-readable media
may store control executable code to be executed by associated
processors including central processing units, and the like. Such
code executable by the processor may include logic to facilitate
the coupling and decoupling operations described herein.
[0061] Indeed, the DCS and associated control system(s) in the
polyolefin production system 10 may include the appropriate
hardware, software logic and code, to interface with the various
process equipment, control valves, conduits, instrumentation, etc.,
to facilitate measurement and control of process variables, to
implement control schemes, to perform calculations, and so on. A
variety of instrumentation known to those of ordinary skill in the
art may be provided to measure process variables, such as pressure,
temperature, flow rate, and so on, and to transmit a signal to the
control system, where the measured data may be read by an operator
and/or used as an input in various control functions. Depending on
the application and other factors, indication of the process
variables may be read locally or remotely by an operator, and used
for a variety of control purposes via the control system.
[0062] A polyolefin manufacturing facility typically has a control
room from which the plant manager, engineer, technician, supervisor
and/or operator, and so on, monitors and controls the process. When
using a DCS, the control room may be the center of activity,
facilitating the effective monitoring and control of the process or
facility. The control room and DCS may contain a Human Machine
Interface (HMI), which is a computer, for example, that runs
specialized software to provide a user-interface for the control
system. The H-IMI may vary by vendor and present the user with a
graphical version of the remote process.
[0063] There may be multiple HMI consoles or workstations, with
varying degrees of access to data.
II. Polymerization Reactor System
[0064] As discussed above, the reactor system 20 may include one or
more polymerization reactors, which may in turn be of the same or
different types. Furthermore, with multiple reactors, the reactors
may be arranged serially or in parallel. Whatever the reactor types
in the reactor system 20, a polyolefin particulate product,
generically referred to as "fluff" herein, is produced. To
facilitate explanation, the following examples are limited in scope
to specific reactor types believed to be familiar to those skilled
in the art and to combinations. To one of ordinary skill in the art
using this disclosure, however, the present techniques are
applicable to more complex reactor arrangements, such as those
involving additional reactors, different reactor types, and/or
alternative ordering of the reactors or reactor types, as well as
various diluent and monomer recovery systems and equipment disposed
between or among the reactors, and so on. Such arrangements are
considered to be well within the scope of the present
invention.
[0065] One reactor type include reactors within which
polymerization occurs within a liquid phase. Examples of such
liquid phase reactors include autoclaves, boiling liquid-pool
reactors, loop slurry reactors (vertical or horizontal), and so
forth. For simplicity, a loop slurry reactor which produces
polyolefin, such as polyethylene or polypropylene, is discussed in
the present context though it is to be understood that the present
techniques may be similarly applicable to other types of liquid
phase reactors.
[0066] FIG. 2 depicts an exemplary polymerization reactor system 20
(of FIG. 1) as having two loop slurry (polymerization) reactors
50A, 50B disposed and operated in series. Of course, additional
loop reactors or other reactors (e.g., gas phase reactors) may be
disposed in series or parallel in the illustrated combination.
Moreover, in embodiments, the reactors 50A, 50B may be shifted to a
parallel operation, and/or processing equipment may be disposed
between the two loop reactors 50A, 50B (see FIG. 13 and FIG. 14,
for example), and so on, providing additional operating and product
flexibility. Indeed, the present techniques contemplate a variety
of reactor system configurations such as those also disclosed in
U.S. Patent Application Publication No. 2011/0288247 which is
incorporated by reference herein in its entirety.
[0067] A loop slurry reactor 50A, 50B is generally composed of
segments of pipe connected by smooth bends or elbows. The
representation of the loop reactors 50A, 50B in FIG. 2 is
simplified, as appreciated by the skilled artisan. Indeed, an
exemplary reactor 50A, 50B configuration may include eight to
sixteen or other number of jacketed vertical pipe legs,
approximately 24 inches in diameter and approximately 200 feet in
length, connected by pipe elbows at the top and bottom of the legs.
FIG. 2 shows a four leg segment reactor arranged vertically. It
could also be arranged horizontally. The reactor jackets 52 are
normally provided to remove heat from the exothermic polymerization
via circulation of a cooling medium, such as treated water, through
the reactor jackets 52.
[0068] The reactors 50A, 50B may be used to carry out polyolefin
(e.g., polyethylene, polypropylene) polymerization under slurry
conditions in which insoluble particles of polyolefin are formed in
a fluid medium and are suspended as slurry until removed. A
respective motive device, such as pump 54A, 54B, circulates the
fluid slurry in each reactor 50A, 50B. An example of a pump 54A,
54B is an in-line axial flow pump with the pump impeller disposed
within the interior of the reactor 50A, 50B to create a turbulent
mixing zone within the fluid medium. The impeller may also assist
in propelling the fluid medium through the closed loop of the
reactor at sufficient speed to keep solid particulates, such as the
catalyst or polyolefin product, suspended within the fluid medium.
The impeller may be driven by a motor 56A, 56B or other motive
force.
[0069] The fluid medium within each reactor 50A, 50B may include
olefin monomers and comonomers, diluent, co-catalysts (e.g., alkyls
such as triethylaluminum and triisobutylaluminum, borates,
triethylboron, methyl aluminoxane, etc.), activator supports like
solid super acids, molecular-weight control agents (e.g.,
hydrogen), and any other desired co-reactants or additives. Such
olefin monomers and comonomers are generally 1-olefins having up to
10 carbon atoms per molecule and typically no branching nearer the
double bond than the 4-position. Examples of monomers and
comonomers include ethylene, propylene, butene, 1-pentene,
1-hexene, 1-octene, and 1-decene. Again, typical diluents are
hydrocarbons which are inert and liquid under reaction conditions,
and include, for example, isobutane, propane, n-butane, n-pentane,
i-pentane, neopentane, n-hexane, cyclohexane, cyclopentane,
methylcyclopentane, ethylcyclohexane, and the like. These
components are added to the reactor interior via inlets or conduits
at specified locations, such as depicted at feed streams 58A, 58B,
which generally corresponds to one of the feed streams 18 of FIG.
1.
[0070] Likewise, a catalyst, such as those previously discussed,
may be added to the reactor 50A via a conduit at a suitable
location, such as depicted at feed stream 60, which may include a
diluent carrier and which also generally corresponds to one of the
feed streams 18 of FIG. 1. Again, the conduits that feed the
various components tie-in (i.e., flange or weld) to the reactor 50.
In the illustrated embodiment, catalyst feed 60 is added to the
first reactor 50A in series but not to the second reactor 50B.
However, active catalyst may discharge in a fluff slurry 21 from
the first reactor 50A to the second reactor 50B. Moreover, while
not depicted, a fresh catalyst may be added to the second reactor
50B in certain embodiments. In total, the added components
including the catalyst and other feed components generally compose
a fluid medium within the reactor 50A, 50B in which the catalyst is
a suspended particle.
[0071] The reaction conditions, such as temperature, pressure, and
reactant concentrations, in each reactor 50A, 50B are regulated to
facilitate the desired properties and production rate of the
polyolefin in the reactor, to control stability of the reactor, and
the like. Temperature is typically maintained below that level at
which the polymer product would go into solution, swell, soften, or
become sticky. As indicated, due to the exothermic nature of the
polymerization reaction, a cooling fluid may be circulated through
jackets 52 around portions of the loop slurry reactor 50A, 50B to
remove excess heat, thereby maintaining the temperature within the
desired range, generally between 150.degree. F. to 250.degree. F.
(65.degree. C. to 121.degree. C.). Likewise, pressure in each loop
reactor 50A, 50B may be regulated within a desired pressure range,
generally 100 to 800 psig, with a range of 450-700 psig being
typical.
[0072] As the polymerization reaction proceeds within each reactor
50A, 50B, the monomer (e.g., ethylene) and comonomers (e.g.,
1-hexene) polymerize to form polyolefin (e.g., polyethylene)
polymers that are substantially insoluble in the fluid medium at
the reaction temperature, thereby forming a slurry of solid
particulates within the medium. These solid polyolefin particulates
may be removed from each reactor 50A, 50B via a settling leg or
other means, or a continuous take-off (CTO), and so on.
[0073] As mentioned, FIG. 2 depicts two loop reactors 50A, 50B in
series. The two loop reactors 50A, 50B may be operated such that
the polyethylene fluff in the fluff slurry 22 discharging from the
second reactor 50B is monomodal or bimodal. In certain cases of
monomodal production, the reactor operating conditions may be set
such that essentially the same polyolefin or similar polyolefin is
polymerized in each reactor 50A, 50B. On the other hand, in the
case of bimodal production, the reactor operating conditions may be
set such that the polyolefin polymerized in the first reactor 50A
is different than the polyolefin polymerized in the second reactor
50B. Thus, with two reactors, a first polyolefin produced in the
first loop reactor 50A and the second polyolefin produced in the
second loop reactor 50B may combine to give a bimodal polyolefin or
a monomodal polyolefin.
[0074] Operation of the two loop reactors 50A, 50B may include
feeding more comonomer to the first polymerization reactor than to
the second polymerization reactor, or vice versa. The operation may
also include feeding more hydrogen to the second polymerization
reactor than the second reactor, or vice versa. Of course the same
amount of comonomer and/or the same amount of hydrogen may be fed
to each reactor 50A, 50B.
[0075] Further, the same or different comonomer concentration may
be maintained in each reactor 50. Likewise, the same or different
hydrogen concentration may be maintained in each reactor 50A, 50B.
Furthermore, the first polyolefin (i.e., polyolefin polymerized in
the first reactor 50A) may have a first range for a physical
property, and the second polyolefin (i.e., polyolefin polymerized
in the second reactor 50B) may have a second range for the physical
property. The first range and the second range may be the same or
different. Exemplary physical properties include polyolefin
density, comonomer percentage, short chain branching amount,
molecular weight, viscosity, melt index, melt flow rate,
crystallinity, and the like.
[0076] Moreover, a differing amount of polyolefin may be produced
in each loop reactor 50A, 50B. For example, the first polyolefin
produced in the first reactor 50A may be 30 weight % to 70 weight %
of the polyolefin product discharging in the product fluff slurry
22 from the second reactor 50B. Likewise, in examples, the second
polyolefin produced in the second reactor 50B may be 30 weight % to
70 weight % of the polyolefin product discharging in the product
fluff slurry 22 from the second reactor 50B. The different amount
of polyolefin production in each reactor 50A, 50B may be
accommodated in loop reactors 50A, 50B of similar or different
size, with different operating conditions, and so on.
[0077] As indicated, the polyethylene product fluff slurry 22
discharges from the second reactor 50B and is subjected to
downstream processing, such as in a diluent/monomer recovery system
24 (see FIGS. 1 and 9-11, for example). The product fluff slurry 22
may discharge through a settling leg, a continuous take-off (CTO),
or other valve configurations.
[0078] The product fluff slurry 22 may discharge intermittently
such as through a settling leg configuration, or instead may
discharge continuously.
[0079] A variety of discharge configurations are contemplated for a
continuous discharge. Employment of an isolation valve (e.g.,
full-bore Ram valve) without an accompanying modulating valve may
provide for continuous discharge of slurry from the loop reactor.
Further, a CTO is defined as a continuous discharge having at least
a modulating flow valve, and provides for a continuous discharge of
slurry from the loop reactor. In certain examples, a CTO is defined
as a continuous discharge having an isolation valve (e.g., Ram
valve) at the reactor wall and a modulating valve (e.g., v-ball
valve) on the discharge conduit at the reactor. A Ram valve in a
closed position may beneficially provide a surface that is flush
with the inner wall of the reactor to preclude the presence of a
cavity, space, or void for polymer to collect when the Ram valve is
in the closed position.
[0080] In operation, depending on the positioning of the discharge
on the reactor, for example, a discharge slurry 22 having a greater
solids concentration than the slurry circulating in the reactor 50B
may be realized with a discharge configuration having an isolation
valve (Ram valve) alone, or having a CTO configuration with an
isolation valve (Ram valve) and modulating valve 25. Exemplary CTO
configurations and control, and other discharge configurations, may
be found in the aforementioned U.S. Patent Application Publication
No. 2011/0288247, and in U.S. Pat. No. 6,239,235 which is also
incorporated herein by reference in its entirety.
[0081] In the illustrated embodiment, the product fluff slurry 22
discharges through a CTO. In certain examples, a CTO has a Ram
valve at the reactor 50B wall, and a modulating flow control valve
25 (e.g., v-ball control valve) on the discharge conduit. Again,
however, in an alternate embodiment, the product fluff slurry 22
may discharge through a settling leg configuration, for example, in
lieu of a CTO.
[0082] A transfer fluff slurry 21 discharges from the first loop
reactor 50A to the second loop reactor 50B via a transfer line 21L.
The contents of transfer fluff slurry 21 may be representative of
the contents of the first loop reactor 50A. However, the solids
concentration may be greater in the transfer slurry 21 than in the
first loop reactor 50A, depending on the positioning of the inlet
of the transfer line 21L on the first loop reactor 50A, for
example, and other considerations. The transfer fluff slurry 21 may
discharge from the first loop reactor 50A into the transfer line
21L through a settling leg, an isolation valve (e.g., a Ram valve),
a continuous take-off (which as indicated the CTO has an isolation
or Ram valve and a modulating valve), or other valve
configuration.
[0083] In the illustrated embodiment, the discharge of the transfer
slurry 21 from the first loop reactor 50A is continuous and not
directly modulated. A CTO or settling leg is not employed. Instead,
the transfer slurry 21 discharges through an isolation valve or Ram
valve (not shown) on the transfer line 21L at the reactor wall and
without a modulating valve in this example. In a particular
example, the transfer slurry 21 discharges through a full-bore Ram
valve maintained in a full-open position, and not additionally
through a modulating valve. In alternate embodiments (not
illustrated) a modulating valve may be disposed downstream on the
transfer line 21L or a CTO with its modulating valve may be
situated at the transfer slurry 21 discharge of the first reactor
50A. If so included, the modulating valve may control flow rate of
the transfer slurry 21 and facilitate control of pressure in the
first loop reactor 50A.
[0084] Nevertheless, in the various embodiments, an isolation
(e.g., Ram) valve is typically disposed on the discharge at the
wall of the first loop reactor 50A. The Ram valve may provide for
isolation of the transfer line 21L from the loop reactor 50A when
such isolation is desired. A Ram valve may also be positioned at
the outlet of the transfer line 21L at the wall of the second loop
reactor 50B to provide for isolation of the transfer line 21L from
the second loop reactor 50B when such isolation is desired. It may
be desired to isolate the transfer line 21L from the first and
second loop reactors 50A, 50B during maintenance or downtime of the
reactor system 20, or when an alternate discharge or transfer line
from the first reactor 50A is placed in service, and so on. The
operation or control of the Ram valves may be manual,
hydraulic-assisted, air-assisted, remote, automated, and so on. The
transfer line 21L may be manually removed from service (e.g.,
manually closing the Ram valves) or automatically removed (e.g.,
via a control system automatically closing the Ram valves) from
service.
[0085] In the illustrated embodiment, control of pressure (and
throughput) in the first loop reactor 50A and the second loop
reactor 50B may be facilitated by operation of the CTO flow control
valve 25. In some examples, the pressure in the first loop reactor
50A may float on the pressure in the second loop reactor 50B. The
reactors 50A, 50B may be maintained at the same, similar, or
different pressure. Pressure elements or instruments may be
disposed on the reactors 50A, 50B and on the transfer line 21L
Further, other process variable elements or instruments indicating
temperature, flow rate, slurry density, and so forth, may also be
so disposed.
[0086] Such instrumentation may include a sensor or sensing
element, a transmitter, and so forth. For a pressure element, the
sensing element may include a diaphragm, for example. For a
temperature element or instrument, the sensing element may include
a thermocouple, a resistance temperature detector (RTD), and the
like, of which may be housed in a thermowell, for instance.
Transmitters may convert a received analog signal from the sensing
element to a digital signal for feed or transmission to a control
system, for example.
[0087] Of course the various instruments may have local indication
of the sense variable. For instance, a pressure element or
instrument may be or have a local pressure gauge and a temperature
element or instrument may be or have a local temperature gauge,
both of which may be read locally by an operator or engineer, for
example.
[0088] The inlet position of the transfer line 21L may couple to
the first loop reactor 50A on the discharge side of the circulation
pump 56A in the first loop reactor 50A. The outlet position of the
transfer line 21L may couple to the second loop reactor on the
suction side of the circulation pump 56B in the second loop reactor
50B. Such a configuration may provide a positive pressure
differential (i.e., a driving force) for flow of transfer slurry 21
through the transfer line 21L from the first loop reactor 50A to
the second loop reactor 50B. In one example, a typical pressure
differential (provided from the discharge of the first pump 54A to
the suction of the second pump 54B) is about 20 pounds per square
inch (psi).
[0089] Lastly, as discussed below, the present techniques provide
the capability to shift the two reactors 50A, 50B from series
operation to parallel (or independent) operation. In certain
embodiments, the transfer slurry 21 is rerouted as a product slurry
27. In alternate embodiments, a product slurry 27 discharges from
another location on the first loop reactor 50A, such as at
different loop elbow on the discharge side of the pump 54A, and the
transfer slurry 21 discharge is discontinued.
III. Polymerization Reactor System--Series and Parallel
Configurations/Operations
[0090] FIGS. 3A-5C are exemplary reactor systems 20 with two loop
reactors 50A, 50B configured to operate in both series and
parallel. The depicted reactor systems 20 are configured to operate
in series but with the capability to "decouple" the two series
reactors 50A, 50B so that they can operate in a parallel, i.e., the
loop slurry reactors 50A, 50B may shift from a coupled series
operation (e.g., FIG. 2) to a decoupled parallel operation, and
vice-versa. In these illustrated examples of FIGS. 3A-5C, in either
series or parallel operation, the second reactor 50B discharges a
fluff product slurry 22 through a CTO modulating valve 25 to the
monomer/diluent recovery system 24. In series configurations, a
transfer slurry 21 discharges from the first reactor 50A to the
second reactor 50B, such as discussed with respect to FIG. 2.
[0091] In parallel configurations, the transfer slurry 21 from the
first reactor 50A to the second reactor 50B may be discontinued,
and instead a fluff product slurry 27 discharges from the first
loop reactor 50A. As discussed below, the fluff product slurry 27
may share the discharge point of the transfer slurry 21 or may have
a different discharge point on the first loop reactor 50A.
Furthermore, the reactor system 20 may be configured to route the
product slurry 27 (i.e., during parallel operation) to different
locations or systems. It should also be noted that existing
adjacent polyolefin lines each having a single polymerization
(loop) reactor may be retrofitted to provide for the depicted
flexibility to operate in parallel and series modes, and thus to
facilitate ease of monomodal and bimodal production, for
example.
[0092] In FIGS. 3A-3C, the product slurry 27 from the first loop
reactor 50A during parallel operation is sent to the
monomer/diluent recovery system 24. The first reactor 50A and the
second reactor 50B feed a fluff product slurry 27 and 22,
respectively, to the same monomer/diluent recovery system 24. As
depicted, the product slurry 27 (i.e., in parallel operation) from
the first reactor 50A may tie into the product slurry 22 from the
second reactor 50B, and share the same flash line in route to the
monomer/diluent recovery system 24. The tie-in of the product
slurry 27 to the product slurry 22 may have a piping configuration
that provides for a relatively smooth transition or meeting of the
product slurries 22 and 27 where possible. In alternate
embodiments, the product slurry 27 from the reactor 50A may instead
first meet the product slurry 22 from the reactor 50B in a vessel
in the recovery system, 24, and not share a conduit or flash line
in route to the recovery system 24. See vessel 64 in FIG. 13 as an
example of such a vessel.
[0093] In FIGS. 4A-4C, the product slurry 27 from the first loop
reactor 50A during parallel operation is sent to another
monomer/diluent recovery system 24A in certain embodiments. As with
the product slurry 22 from the reactor 50B, the product slurry 27
from reactor 50B may be routed through a flash line having a jacket
heater, for example. The second monomer/diluent recovery system 24A
may be a portion of a parallel polyolefin line, associated with a
parallel reactor system, and/or associated with a parallel
extrusion system, for example. On the other hand, the second
monomer/diluent recovery system 24A may not be associated with a
parallel polyolefin line. Of course, other dispositions of the
second monomer/diluent recovery system 24 are contemplated.
[0094] In alternate embodiments, the product slurry 27 from the
first loop reactor 50A during parallel operation may discharge to
the same diluent/monomer recovery system 24 (and not to a second
monomer/diluent recovery system 24A). In this case in certain
examples, the product slurry 27 and the product slurry 22 first
meet in a separation vessel (e.g., flash vessel) of the recovery
system 24, and do not share a conduit or flash line in route to the
recovery system 24. For example, the product slurries 22 and 27
enter such a separation vessel through respective inlet nozzles on
the separation vessel as depicted in FIG. 13, for instance.
[0095] In FIGS. 5A-5C, the product slurry 27 from the first loop
reactor 50A during parallel operation to be sent to either
monomer/diluent recovery system 24 or 24A. Of course, as indicated,
in these exemplary reactor system 20 configurations of FIGS. 3A-5C,
the product slurry 27 may generally be routed through a flash line
heater prior to entry into a flash vessel in the monomer/diluent
recovery systems 24 or 24A.
[0096] The reactor systems 20 in FIGS. 5A-5C have the combined
capability of FIGS. 3A-3C and 4A-4C, respectively, with a diverter
valve or three-way valve 29, for example. The 3-way valve 29 (and
other 3-ways valves in the system 10) may have one inlet and two
outlets in certain embodiments. The fluid passageway in a 3-way
ball valve may be Y-shaped (i.e., Y-type), T-shaped, and so on. In
one example, the 3-way valve is a Y-type 3-way ball valve, for
example. The 3-way valve and associated piping may generally
provide for a relatively smooth transition in the slurry flow
between the two outlet flow paths through the 3-way valve.
Moreover, diverter valves other than the described 3-way valve may
be employed. The present techniques accommodate the general concept
of diverting slurries (and solids streams) in a variety of
ways.
[0097] Again, with regard to FIGS. 3A-5C generally, during series
operation in the reactor system 20, a transfer slurry 21 discharges
from the first loop reactor 50A to the second loop reactor 50B. In
the operating shift from series to a decoupled or parallel
performance of the reactors 50A, 50B, the transfer slurry 21 may be
stopped, and a product slurry 27 initiated from the first loop
reactor 50. To discontinue operation of the transfer slurry 21, a
respective isolation valve or RAM valve (not shown) at each end of
the transfer line at the reactors 50A, SOB may be closed, for
example. As for the fluff product slurry 27 (i.e., in the shift to
parallel operation), the product slurry 27 may originate from the
first loop reactor 50A in different ways. FIGS. 3A-5C give example
configurations of the discharge of the product slurry 27 from the
first loop reactor 50A.
[0098] FIGS. 3A, 4A, and 5A represent the product slurry 27 as
originating from a different discharge location on the first loop
reactor 50A than the discharge location of the transfer slurry 21.
For instance, as discussed with respect to FIG. 2 above, the
discharge of fluff product slurry 27 may be positioned on a
different pipe elbow on the loop reactor 50A than the discharge for
the transfer slurry 21L. Such a discharge for the product slurry 27
may be configured with a CTO such as an isolation valve or RAM
valve (not shown) and a modulating valve 31 (e.g., v-ball control
valve). As with fluff slurry discharges generally from loop
reactors in embodiments of the present techniques, the discharge of
the product slurry 27 may be configured and positioned on the loop
reactor 50A such that the solids concentration in the product
slurry 27 is greater than the solids concentration in of the slurry
circulating in the loop reactor 50A.
[0099] FIGS. 3B, 4B, and 5B depict the product slurry 27 sharing
the same or similar discharge location on the first loop reactor
50A as the transfer slurry 21. In these examples, the opening
position of a 3-way valve 33 at the discharge may be rotated to
shift between series and parallel operation. In series operation,
the flow path of the 3-way valve 33 is set such that a transfer
slurry 21 exits through an outlet of the valve 33 to the second
reactor 50B. Conversely, in parallel operation, the flow path of
the 3-way valve 33 is set to block the valve 33 outlet to the
second reactor and instead route a product slurry 27 through the
other outlet of the valve 33. The product slurry 27 exiting the
valve 33 flows through a modulating valve 31 in this example.
[0100] FIGS. 3C, 4C, and 5C depict the product slurry 27 sharing
the same or similar discharge location on the first loop reactor
50A as the transfer slurry 21. In this example, the modulating
valve 31 is disposed upstream of the 3-way valve 33. The modulating
valve 31 may be part of a CTO configuration on the loop reactor
50A. In parallel operation of the two loop reactors 50A, 50B, the
control valve 31 may regulate the flow rate of the product slurry
27 and the pressure in the reactor 50A, as with a typical CTO
configuration. Further, in parallel operation, the opening position
or flow path of the downstream 3-way valve 33 may be set to route
the product slurry 27 away from the reactor 50B. Conversely, in
series operation, the modulating valve 31 may be maintained in a
full-open position and a transfer slurry 21 routed to the second
loop reactor 508 through the 3-way valve. In certain instances, it
may be desired to utilize the discharge modulation of the valve 31
in series operation such as when desired to regulate the transfer
slurry 21 flow rate or to regulate pressure in the first reactor
50A, and so on.
[0101] FIGS. 6A-6C depict portions of two polyolefin production
lines 10-1 and 10-2 having a single loop reactor 50-1 and 50-2,
respectively, and also a respective monomer/diluent recovery system
24-1 and 24-2 in this example. The loop reactor 50-1 of the first
line 10-1 may discharge a fluff product slurry 22-1 through a CTO
having a modulating valve 25-1 and through a flash line having a
jacket heater (not shown) to a monomer/diluent recovery system
24-1. Likewise, the reactor 50-2 of the second line 10-2 may
discharge a fluff product slurry 22-2 through a CTO having a
modulating valve 25-2 and through a flash line having a jacket
heater (not shown) to a monomer/diluent recovery system 24-2. This
operation may be characterized as a parallel operation of the two
reactors 50-1 and 50-2. The respective portions of the two
polyolefin production lines 10-1 and 10-2 may reside at the same
manufacturing site or facility, and in certain cases may be near or
adjacent one another.
[0102] In FIG. 6A, the two reactors 50-1 and 50-2 may be shifted
from parallel operation to series operation. In this example for
series operation, a 3-way valve 33 may divert the product slurry
flow 22-1 from the loop reactor 50-1 to the loop reactor 50-2.
Thus, in this series operation, the product slurry flow 22-1 from
the loop reactor 50-1 may be characterized as a transfer slurry 21
from a first loop reactor 50-1 to a second loop reactor 50-2.
Therefore, the two reactors 50-1 and 50-2 may be decoupled for
parallel operation or coupled in series operation. It should be
noted that FIG. 6A is similar or analogous to FIG. 4C, but with
FIG. 6A having an illustrated perspective of two adjacent
polyolefin production lines.
[0103] In FIG. 6B, the fluff product slurry 22-1 from the loop
reactor 50-1 may be sent to the monomer/diluent recovery system
24-1 or diverted to the diluent/monomer recovery system 24-2. Such
diversion may be beneficial, for example, when desired to blend
product slurry discharges from two loop reactors, or when desired
to shut down the diluent/monomer recover system 24-1 for inspection
or maintenance, and so forth. The diluent/monomer recovery system
24-2 may be sized accordingly, i.e., to handle product slurry
discharges from two loop reactors.
[0104] In the illustrated embodiment, the product slurry 22-1 from
the loop reactor 50-1 may be diverted to the recovery system 24-2
through the 3-way valve 33A or the 3-way valve 33B. If diverted
through the first 3-way valve 33A, the product slurry 22-1 shares
the flash line 37-2 with the product slurry 22-2. On the other
hand, if diverted through the second 3-way valve 33B, the product
slurry 22-1 flows through the flash line 37-1 and first meets the
product slurry 22-1 in a separation or flash vessel in the recovery
system 24-2. Such a vessel may have two inlet nozzles to receive
two respective product fluff slurries (see FIG. 13 as an
example).
[0105] FIG. 6C depicts a combination of the capability shown in
FIGS. 6A and 6B. First, the product slurry 22-1 that discharges
from the loop reactor 50-1 may be routed through a flash line 37-1
to the monomer/diluent recovery system 24-1. Second, the product
slurry 22-1 that discharges from the loop reactor 50-1 may be
diverted through the 3-way valve 33A and an additional 3-way valve
35 (introduced in FIG. 6C) as either: (1) a transfer slurry 21 to
the loop reactor 50-2 for reactor series operation; or (2) a
product slurry 22-1 to the monomer/diluent recovery system 24-2
(e.g. via sharing the same flash line 37-2 with the product slurry
22-2 discharging from the loop reactor 50-2). Third, as with FIG.
6B, the 3-way valve 33B downstream of the flash line 37-1 may
divert the fluff product slurry 22-1 to the recovery system 24-2.
Lastly, it should be noted that FIG. 6C is similar or analogous to
FIG. 5C, but with FIG. 6C having an illustrated perspective of two
adjacent polyolefin production lines.
[0106] In FIG. 7, a loop reactor 50 simultaneously discharges to
two monomer/diluent recovery systems 24A and 24B. Such may be
beneficial, for example, when desired to discharge a reactor
polyolefin product slurry to two different post-reactor treatment
zones at the same time. The depicted loop reactor 50 may be a sole
reactor or parallel reactor, or a terminal reactor of a series of
reactors, in a reactor system 20. The product slurry 22 discharging
from the loop reactor 50 divides and flows through both parallel
modulating control valves 25A and 25B to the respective
monomer/diluent recovery system 24A and 24B. Each of the slurries
22A and 22B may flow through a respective flash line heater.
[0107] The illustrated example shows the fluff product slurry 22
discharging from a single location on the loop reactor 50, and then
split into two fluff product slurries 22A and 22B. However, in an
alternate example (not shown), the two product slurries 22A and 22B
originate from two respective locations on the reactor 50. In
either case, the slurries 22A and 22B flow through the respective
control valves 25A and 25B and different flash lines to different
recovery systems 24A and 24B, as discussed.
[0108] The modulating valves 25A and 25B may regulate flow rate of
their respective product slurry 22A and 22B, as well as regulate
the pressure in the reactor 50, for example.
[0109] In a first control example, the flow rate of each slurry 22A
and 33B is measured with a respective mass meter, for instance, and
the each control valve 25A and 25B modulated to control the
measured slurry 22A and 22B flow rates to a respective set point.
In a second control example, one of the modulating valves 25A or
25B is maintained at a fixed open (percentage) position and the
other modulating valve 25A or 25B is modulated to regulate the
total product slurry flow rate from the loop reactor 50 and the
pressure in the loop reactor 50. Of course, other control logic may
be implemented.
[0110] FIG. 8 is a reactor system, having two reactors 50-1 and
50-2 that may operate in parallel and discharge respective product
slurries 22-1 and 22-2 to respective monomer/diluent recovery
systems 24-1 and 24-2. As for the reactor 50-2 in such parallel
operation, the control valve 25-2B may remained closed, and the
control valve 25-2A in operation, for example.
[0111] Further, the two reactors 50-1 and 50-2 may be coupled
operationally in series such that the reactor 50-1 is the first
reactor in the series and feeds its product slurry 22-1 as a
transfer slurry 21 to the reactor 50-1 which is the second or
terminal (final) reactor in the series. Similar to the loop reactor
in FIG. 7, the second reactor 50-2 in FIG. 8 in series operation
discharges product slurry simultaneously to two monomer/diluent
recovery systems 24A and 24B. Such an installation may be
grassroots. On the other hand, adjacent polyolefin production lines
may be retrofitted with the depicted capability. A benefit may be
to facilitate production of various polyolefin monomodal and
bimodal polymer products, as indicated above.
IV. Diluent/Monomer Recovery System
[0112] FIG. 9 an exemplary diluent/monomer recovery system 24. At
the outset, it should be emphasized that the diluent/monomer
recovery system 24 (see also FIG. 1) discussed herein and that
receives and processes the discharge slurry 22 from the reactor
system 20 is given as exemplary. Indeed, a variety of other
equipment, configurations and unit operations may be employed to
remove or separate diluent, monomer, and other components from the
polyolefin (e.g., polyethylene) product fluff slurry 22.
[0113] The polyolefin product fluff slurry 22 discharging from the
loop reactor (e.g., reactor 50B of FIG. 2) flows through a flash
line having an in-line flash heater 62, and into a separation
vessel 64. The separation vessel 64 may be a flash vessel, a flash
chamber, a simple settling drum, a high efficiency cyclone, or
combination of cyclone and flash chamber, or other suitable device
to separate the solids from the majority of the diluent. The
diluent/monomer recovery system 24 may be defined as incorporating
the flash line and in-line flash heater 62. On the other hand, the
diluent/monomer recovery system 24 may be defined as excluding such
and instead beginning with the separation vessel 64, and thus the
flash line and in-line flash heater 62 disposed between the reactor
system 20 and the recovery system 24.
[0114] The in-line flash heater 62 may be a surrounding conduit or
jacket that uses steam or steam condensate, for example, as a
heating medium to provide indirect heating to the slurry 22. Thus,
the loop slurry reactor effluent (such as product fluff slurry 22
from the second loop reactor 50B of FIG. 2, or other terminal
reactor or combination of loop reactors) is heated prior to its
introduction into the separation vessel 64 (e.g., flash chamber).
Further, the slurry 22 may generally experience a pressure
reduction through the flash line and therefore vaporization of
non-solid components prior to entering the separation vessel 64 due
to both pressure decrease and temperature increase through the
flash line. As indicated, above, the flash line and the surrounding
conduit or jacket heater is configured to volatize the diluent and
to increase enthalpy of the slurry 22. The liquid hydrocarbon in
the product slurry 22 may be partially vaporized or substantially
fully vaporized prior to entry of the slurry 22 into the separation
vessel 64. Also, before the product fluff slurry 22 enters the
separation vessel 64, water or other catalysts poisons may be
injected into the slurry 22 to deactivate any residual catalysts
and cocatalysts in the slurry 22. Because these injected components
are generally catalysts poisons, they are typically completely
removed, or at least substantially removed, from any recovered
material (e.g., monomer or diluent) recycled to the reactors 50A,
50B, 50-1, 50-2, etc.
[0115] The separation vessel 64 has an entry to receive the product
fluff slurry 22, which may be a nozzle or other inlet type. In
certain embodiments, the entry on the separation vessel 64 may be a
tangential entry (e.g., tangential entry nozzle), as appreciated by
the skilled artisan. Further, according to the present techniques,
the separation vessel 64 may have two or more entries or inlet
nozzles (only one is shown) to receive parallel fluff slurries. See
FIG. 13 as an example. In other examples of the present techniques,
the separation vessel 64 may receive, through a single inlet, two
or more product fluff slurries combined in the upstream flash line.
In either case, the separation vessel may be sized to accommodate
the mass and volume of two or more product fluff slurries. For
instance, the volume of the separation vessel 64 may be larger.
Further, the disengagement section of the separation vessel may be
affected. Whether receiving one slurry or multiple slurries, the
separation vessel 64 that receives the fluff product slurry 22 from
the loop reactor may be a high-pressure flash or low-pressure flash
(e.g., 7 psig), a collecting vessel, or other configurations, and
so forth. With a high pressure flash, the vaporized hydrocarbon
(e.g., flash gas 66 which may include diluent, monomer, comonomer)
beneficially may not need compression prior to condensation and
recycle, i.e., recycled to the feed system 16 (FIG. 1) and reactor
system 20. In contrast, the vaporized hydrocarbon from a
low-pressure flash is generally compressed prior to condensation
and recycles to the feed system 16 and reactor system 20. Exemplary
operating pressures are in the range of 0 psig to 15 psig for a
low-pressure flash, and in the range of 120 psig to 450 psig for a
high-pressure flash depending on the diluent employed, for
example.
[0116] An additional flash vessel (not shown) may be disposed
between the separations (flash) vessel 64 and the purge column 68.
The additional flash vessel receives the solids stream from the
separation vessel 64 and discharges a solids stream to the purge
column 68. In one example, the separation vessel 64 is a
high-pressure flash, and the additional flash vessel (not shown) is
a low-pressure flash. In another example, the separation vessel 64
is a high-pressure flash, low-pressure flash, or collecting vessel,
and the additional flash vessel (not shown) is a concentrator (or
one or more concentrators in parallel) which may have intake and
outlet valves. In examples of the separation vessel 64 as a
collecting vessel, the polyolefin fluff settles in the collecting
vessel. The concentrators as the additional vessel may beneficially
reduce the amount of vapor or gas transferred from the separation
vessel 64 to the purge column 68.
[0117] However, again, a single separation flash vessel 64, as
depicted, may be employed and that discharges the fluff solids to
the purge column 68. Thus, in this latter case, the capital and
operating costs of a second flash or second major vessel generally
are not incurred. Moreover, in the embodiments of the separation
vessel 68 as a high-pressure flash, the flashed hydrocarbon (flash
gas 66) from the separation vessel 64 generally need not be
compressed.
[0118] In the flash chamber 64 (e.g., or more generally a
separation vessel), whether low pressure or high pressure, most of
the non-solid components of the reactor discharge slurry 22 are
withdrawn overhead as vapor in the flash gas 66 and recycled to the
reactor system 20 (i.e., via the feed system 16). The condensed
flash gas 66 may be may bypass 34 the fractionation system 30 in
mute to a reactor 50 (i.e., via the feed system 16), for example
(see also FIG. 1). On the other hand, all or a portion of the flash
gas 66 (as vapor and/or condensed liquid) may be sent to the
fractionation system 30 (see also FIG. 1).
[0119] In polyethylene production, this flash gas 66 is typically
primarily diluent, such as isobutane or other diluents previously
mentioned. It may also contain most of the unreacted monomer (e.g.,
ethylene) and other light components, as well as unreacted
comonomer (e.g., 1-hexene, butene, 1-pentene, 1-octene, and
1-decene) and other heavy components (e.g., hexane and oligomers).
An exemplary approximate composition of the flash gas 66 for a
high-pressure flash is 94 wt. % isobutane, 5 wt. % ethylene, and 1
wt. % other components. A level or volume of fluff may be
maintained in the flash chamber 64 to give additional residence
time of the fluff in the chamber 64 to facilitate separation of
liquid and vapor entrained in the porous fluff particles.
[0120] The flash gas 66 may be processed in equipment such as
cyclones, bag filters, etc., where entrained fluff solids are
removed and returned to the flash chamber 64 or to downstream
equipment, such as the purge column discussed below. The flash gas
66 may also travel through a de-oxygenation bed, for example.
Furthermore, as indicated, the flash gas 66 may be cooled or
condensed in a heat exchanger (e.g., shell-and-tube construction)
prior to its recycle to the feed system 16 or fractionation system
30 (see also FIG. 1). Beneficially, in part because of the
operating pressure of the flash chamber 64 in certain embodiments,
such cooling, condensation, and direct recycle of the flash gas 66
may be performed without compression in some examples, such as with
a high-pressure flash. The flash gas 66 may correspond to part or
all of recycle streams 26 and 34 of FIG. 1 in certain examples.
[0121] As for the solids (polymer) in the flash chamber 64, they
are withdrawn with a small amount of entrained diluent (and
monomer) and sent to a purge column 68 via solids discharge 70. As
will be appreciated by those of ordinary skill in the art, the
solids discharge 70 conduit may include valve configurations that
allow polymer to flow downward through the conduit while reducing
the potential for vapor to flow between the purge column 68 and the
flash chamber 64. For example, one or more rotary or cycling
valves, a single v-ball control valve, fluff surge tanks,
relatively small fluff chamber, and so on, may be disposed on the
solids discharge 70 conduit. Moreover, a level of solids may be
maintained in the flash chamber 64 via a level control valve at the
base of the flash chamber 64 or on the solids discharge conduit 70,
providing for increased residence time of the solids in the flash
chamber 64.
[0122] In more traditional configurations with the flash chamber 64
as a high-pressure flash, the fluff solids from the flash chamber
64 may discharged into a lower pressure flash chamber, as discussed
above, with the lower pressure flash gas requiring compression for
recycle to the reactor. However, newer technologies have provided
for elimination of a low-pressure flash and the associated gas
compression, and instead discharge of the fluff solids from a
high-pressure flash chamber 64 to the purge column 68.
[0123] In the illustrated embodiment, the primary solids feed to
the downstream purge column 68 is typically the solids discharge 70
(polyolefin fluff) that exits the flash chamber 64. A purpose of
the purge column 68 is to remove residual hydrocarbon from the
entering solids streams and to provide substantially-clean polymer
fluff 28 with at most relatively small amounts of entrained
volatile organic content (VOC). The fluff 28 may be transported or
conveyed to the extrusion system 36 (see FIG. 1 and FIG. 15) for
conversion to pellets 38, and for distribution and sale as
polyolefin pellet resin to customers 40 via loadout system 39 (see
FIG. 1 and FIG. 15). In general, the treated polymer particles
discharged from purge column 68 as polymer fluff 28 may be
processed in a conventional finishing operation, such as a twin
screw extruder, in the extrusion system 36 (FIG. 1).
[0124] In the exemplary purge column 68 system illustrated,
nitrogen is injected into a purge column 68 to remove or displace
residual hydrocarbons via overhead discharge 74. This discharge 74
may be sent through a separation unit 76, such as a membrane
recovery unit, pressure swing adsorption unit, refrigeration unit,
and so forth, to recover nitrogen via nitrogen stream 78, and to
discharge a separated hydrocarbon stream 80 which may be compressed
and fed to the fractionation system 30, for example. This separated
hydrocarbon stream 80 may correspond to a portion of stream 26 of
FIG. 1 in certain examples. In the art, the separation unit 76 may
be known as a Diluent Nitrogen recovery Units (DNRU). Isobutane
Nitrogen Recovery Unit (INRU), and the like. Moreover, fresh
nitrogen 82 may be added to the nitrogen circuit to account for
nitrogen losses in the purge column 68 system. Finally, it should
be noted that the hydrocarbon stream 80 discharging from the
separation unit 76 may be compressed and processed in the
fractionation system 30 (FIG. 1) to give olefin-free diluent used
in catalyst preparation and reactor or line flushes.
[0125] Lastly, as will be appreciated by those of ordinary skill in
the art, a variety of configurations may be employed in the
diluent/monomer recovery system 24. For example, the solids
discharge 70 from the flash chamber 64 may be sent to another
reactor (e.g., a liquid phase reactor or gas phase reactor) or to a
low-pressure flash chamber instead of to the purge column 68. The
polymer may then later enter the purge column 68 (i.e., from the
additional reactor or low-pressure flash chamber). If discharged to
another reactor from the flash chamber 64, catalyst poison is
generally not injected upstream in the discharge 22, and, thus,
residual active catalysts remain for further polymerization. In
another configuration, the purge column 68 may be eliminated from
the recovery system 20 and combined with the downstream extruder
feed tank, and residual hydrocarbon or volatile organic (VOC)
removal performed in such a combination. Indeed, the separation
unit 76 associated with the purge column 68 may be relocated to
accommodate the purge column/extruder feed tank combination, for
example. Of course a variety of other configurations and types of
vessels and equipment are contemplated in the present
techniques.
[0126] FIGS. 10 and 11 are alternate embodiments that split fluff
solids streams in the monomer/diluent recovery system 24. Two
treated fluff solids stream 28A and 28B are discharged from the
monomer/diluent recovery system 24, and may be sent to different
extruder feed tanks. Such may be beneficial, for example, if
desired to feed two different extruder systems 36A and 36B. Such
configuration and operating flexibility may be advantageous in
addressing capacity concerns of extrusion systems, and/or the
desire to use different respective additive packages in the two
extrusion systems, and so forth. Moreover, it should be noted that
the separation vessel 64 may be configured to receive more than one
product fluff slurry 22, as discussed above with respect to FIG. 9.
Again, for example, two product slurries 22 may be combined in the
upstream flash line, or may be received separately at the
separation vessel 64 via two inlet nozzles and combined in the
separation vessel 64.
[0127] FIG. 10 is an alternate embodiment of the monomer/diluent
recovery system 24 in having two purge columns 68A and 68B in
parallel. The separation vessel 64 (e.g., flash chamber or flash
drum) receives the fluff product slurry 22 from the reactor system
20. The separations vessel 64 may be a high-pressure flash or
low-pressure flash. In the illustrated embodiment, the separations
vessel 64 discharges two solids streams 70A and 70B, such as via
two bottom discharge nozzles on the vessel 64 and each discharge
nozzle or conduit having a level control valve (not shown), for
example. An exemplary control scheme may involve operating one of
the level control valves at a fixed open position, and with the
other level control valve modulating to control the fluff solids
level in the vessel 64. The two solids streams 70A and 70B
discharge to the two respective purge columns 68A and 68B. The two
purge columns 68A and 68B may discharge respective treated fluff
solids streams 28A and 28B to different extruder feed tanks, for
example.
[0128] FIG. 11 is an alternate embodiment of the monomer/diluent
recovery system 24. The separation vessel 64 (e.g., flash chamber,
flash drum, etc.) receives the fluff product slurry 22 from the
reactor system 20. The separations vessel 64 may be a high-pressure
flash or low-pressure flash. In the illustrated embodiment, the
separations vessel discharges a fluff solids stream 70 to the purge
column 68. In this alternate embodiment, the purge column 68
discharges two solids streams 28A and 28B, such as via two bottom
discharge nozzles on the purge vessel 68 and with each discharge
nozzle or conduit having a level control valve (not shown), for
example. An exemplary control scheme may involve operating one of
the level control valves at a fixed open percentage position, and
with the other level control valve modulating to control the fluff
solids level in the vessel 68. The two treated fluff solids streams
28A and 28B may be sent to different respective extruder feed
tanks, for example.
[0129] FIG. 12 depicts two monomer/diluent recovery systems 24-1
and 24-2 that may be coupled and decoupled in operation. The two
monomer/diluent recovery systems 24-1 and 24-2 may be disposed at
the same manufacturing facility and each a portion of a respective
polyolefin production line, for example. In certain examples, the
monomer/diluent recovery systems 24-1 and 24-2 may be near or
adjacent one another. Moreover, the coupling/decoupling capability
depicted in FIG. 12 and explained below may be installed
grassroots. On the other hand, such capability may be installed as
a retrofit of an existing installation, e.g., a retrofit of two
independent recovery systems 24-1 and 24-2 near or adjacent one
another. In either case, the separation vessels (64-1 and 64-2 may
be equipped to receive multiple product slurries as discussed above
with respect to FIG. 9.
[0130] Nevertheless, in the recovery system 24-1, the separation
vessel 64-1 (e.g. flash drum) is capable to receive a polyolefin
fluff product slurry 22-1 from a loop reactor 50-1, and to
discharge a fluff solids stream 70-1 to a purge column 68-1. The
purge column 68-1 treats the fluff solids to remove residual
hydrocarbon and discharges treated fluff solids 28-1 to an extruder
feed tank in the extrusion system 36-1. A level of fluff solids in
the separation vessel 64-1 may be maintained via a level control
valve (not shown) on the discharge of the separation vessel 64-1
and that regulates the flow rate of the fluff solids stream 70-1.
Similarly, a level of fluff solids in the purge column 68-1 may be
maintained via a level control valve (not shown) on the discharge
of the purge column 68-1 and that regulates flow rate of the fluff
solids 28-1.
[0131] Likewise, in the recovery system 24-2, a separation vessel
64-2 (e.g., flash drum) is capable to receive a polyolefin fluff
product slurry 22-2 from a loop reactor 50-2, and to discharge a
fluff solids stream 70-2 to a purge column 68-2. The purge column
68-2 treats the fluff solids to remove residual hydrocarbon and
discharges treated fluff solids 28-2 to an extruder feed tank in
the extrusion system 36-2. A level of fluff solids in the
separation vessel 64-2 may be maintained via a level control valve
(not shown) on the discharge of the separation vessel 64-2 and that
regulates the flow rate of the fluff solids stream 70-2. Similarly,
a level of fluff solids in the purge column 68-2 may be maintained
via a level control valve (not shown) on the discharge of the purge
column 68-2 and that regulates flow rate of the fluff solids 28-2.
Such foregoing operations of the two systems 24-1 and 24-2 may be a
decoupled parallel operation.
[0132] In coupled operations, the separation vessel 64-1 if
involved, i.e., receives a fluff product slurry 22-1 from the loop
reactor 50-1, discharges to the purge column 68-1 and/or purge
column 68-2. Therefore, operationally, the separation vessel 64-1
may discharge to the purge column 68-2 in addition to or in lieu of
discharging to the purge column 68-1. Further, the purge column
68-1 if involved in the coupled operation, i.e., receives the
solids stream 70-1 from the separation vessel 64-1, discharges to
the extrusion system 36-1 and/or extrusion system 36-2. Thus, the
purge column 68-1 may discharge to the extrusion system 36-2 in
addition to or in lieu of discharging to the extrusion system 36-1.
Therefore, the coupled operations in FIG. 12 may provide for
splitting, diverting, and combining fluff solids streams, giving
operation, maintenance, and product flexibility.
[0133] Examples of the one or two discharges from each of the
separations vessel 64-1 and the purge column 68-1 may involve two
discharges from each vessel (e.g., two discharge nozzles on each
vessel) with each discharge having a level control valve. Thus,
when two fluff solids streams discharge from a given vessel (i.e.,
from 64-1 or 68-1), the level control valve on each discharge may
operate, or one level control valve may be maintained at a constant
open percentage position, and the other level control valve
modulated to regulate the solids level in the vessel. For the case
of an operation giving a single discharge of fluff solids, one of
the level control valves may be closed, or a single physical
discharge from the vessel may be employed and a diverter valve or
3-way valve used to route a single fluffsolids stream.
[0134] Thus, in coupled operations, the separation vessel 64-1 may
discharge to the purge column 68-2 in addition to simultaneously
discharging to the purge column 68-1, such as via an additional
(second) discharge and additional (second) level control valve (not
shown). The separation vessel 64-1 may also discharge to the purge
column 68-2 in lieu of discharging to the purge column 68-1, such
as by closing the level control valve on the first discharge, or by
discharging via the first discharge and through a diverter or 3-way
valve (not shown), for example. Further, in coupled operations, the
separation vessel 64-1 may discharge to the extrusion system 36-2
in addition to discharging simultaneously to the extrusion system
36-1, such as via an additional discharge and additional level
control valve (not shown). Operationally, the separation vessel
64-1 may also discharge to the extrusion system 36-2 in lieu of
discharging to the purge column 68-1, such as via the first
discharge and a diverter or 3-way valve (not shown), for example.
Lastly, it should be noted that the product fluff slurry 22-1 from
the loop reactor 50-1 may be split or diverted to the separation
vessel 64-1, such as via concepts discuss with respect to FIGS.
6A-8.
[0135] FIG. 12 may be characterized as depicting the respective
monomer/diluent recovery systems 24-1 and 24-2 of two polyolefin
production lines both having a respective loop reactor 50-1 and
50-2. As indicated, the loop reactor 50-1 of the first line 10-1
may discharge a fluff product slurry 22-1 through a heated flash
line to the monomer/diluent recovery system 24-1. Likewise, the
reactor 50-2 of the second line 10-2 may discharge a fluff product
slurry 22-2 through a heated flash line to the monomer/diluent
recovery system 24-2. This operation may be characterized as a
parallel operation of the two reactors 50-1 and 50-2. These
respective portions of the two polyolefin production lines may
reside at the same manufacturing facility, and in certain cases may
be near or adjacent one another.
[0136] FIG. 13 depicts the separation vessel 64 as capable to
receive two fluff product slurries 22A and 22B from one or more
reactor systems 20 (through respective flash line inline heaters
62A and 62B). In certain embodiments, the flash lines including
their inline heaters 62B and 62B are considered part of the reactor
system(s) or as disposed between the reactor systems and the
diluent/monomer recovery system 24. In the illustrated embodiment,
the recovery system 24 (and the post-reactor fluff treatment
system) is defined as beginning with the separation vessel 64, as
indicated by reference line 8. The separation vessel 64 has two
inlets to receive the respective fluff product slurries 22A and 22B
which first meet in the separation vessel 64 and do not meet in an
upstream conduit or flash line.
[0137] As indicated above, the two entries on the exemplary
separation vessel 64 in the illustrated embodiment may each be
tangential entry (e.g., tangential entry nozzle). On the other
hand, one or both of the entries may be a simple nozzle. Further,
the separation vessel 64 may be sized to accommodate the mass and
volume of two or more product fluff slurries 22A and 22B. For
instance, the volume, height, width, and disengagement section of
the separation vessel 64 may be larger.
V. Extrusion System and Loadout System
[0138] FIG. 14 is a process flow diagram of an exemplary extrusion
system 36 and exemplary loadout system 39 of FIG. 1. Polyolefin
fluff 28 from the purge column 68 (e.g., FIG. 9) may be
pneumatically transferred, for example, using a dilute phase
blower, through a valve 340 (e.g., a diverter or 3-way valve) in
the extruder system 36, and either into conduit 342 to the fluff
silo 344, or into conduit 346 to the extruder feed tank 348. The
fluff silo 344 may be used to provide surge capacity during
shutdown of the extruder (or of other operations) in the extrusion
system 36. On the other hand, the fluff silo 344 may also
accumulate fluff to allow for full-rate operation of the extruder
while the upstream polymerization reactors 50A, 50B "catch up"
during startup of the reactors 50A, 50B. The polyolefin fluff in
silo 344 may be pneumatically transferred to the extruder feed tank
348 through rotary valve 350 with the aid of a blower system (not
shown).
[0139] Typically, however, the primary flow of polyolefin fluff 28
is to the extruder feed tank 348 via conduit 346. Downstream,
rotary valve fluff 352 may feed polyolefin fluff 354 to the
extruder 356, where the extruder heats, melts, and pressurizes the
polyolefin fluff 354. As will be appreciated by those of ordinary
skill in the art, the fluff 354 from the extruder feed tank 348 may
be metered to the extruder 356 with a variety of meters, such as
smart flowmeter-type, master-feeder type, and so forth.
[0140] Furthermore, additives may be injected into the fluff 354
stream at an addition rate which may be based on a specified ratio
to the mass flow rate of the fluff 354. This ratio or "slave" feed
of additives to fluff 354 may be specified at a value to generate a
desired recipe, for example, for each polyolefin grade or product,
and to give the desired properties of the downstream polyolefin
pellets. Furthermore, the additive addition may be accomplished
with a liquid additive system, loss-in-weight-feeders, and the
like. In certain embodiments, one or more of lost-in-weight feeders
may be used to meter a pre-mixed additive package fed from a bulk
container, for example, to the extruder 356 via the fluff 354
stream, via an extruder feed hopper (not shown), or directly to the
extruder 356 such as with injection into the polyolefin melt in the
extruder 356, and so on. As mentioned above with respect to FIG. 1,
additives or additive packages placed into the extruder feed or
into the extruder (e.g., injected into the melt channel of the
extruder) may include surface modifiers (e.g. slip agents,
antiblocks, tackifers), UV inhibitors, antioxidants (e.g.,
phenolics, phosphites, thioesters, amines, etc.), colorants,
pigments, processing aids (e.g., flow promoters such as waxes &
oils and fluoroeslastomers), peroxides, and other additives.
[0141] The surface modifiers may alter the surface characteristics
of a film or coating subsequently-formed from the pellets 38 to
control coefficient of friction (COF) or tackiness. For example,
surface modifiers that are slip agents (e.g., stearamide, oleamide,
erucamide, etc.) may reduce the COF of the subsequently-formed
films and coatings. Surface modifiers that are antiblocks may
reduce sticking together of adjacent film surfaces such as in a
roll of finished bags, for instance. Surface modifiers as
tackifiers (e.g., polyisobutene or PIB) may be added in either dry
form (e.g., masterbatch addition) to the extruder feed or injected
as a liquid into the melt channel of the extruder, to promote
stickiness and "cling" between adjacent film surfaces, such as with
the manufacture of polyethylene stretch films, for instance.
[0142] Specialized additives may be added to improve a specific
performance attribute. Other additives may include fire retardants
(to reduce flammability of the polyolefin resin), antistats (to
reduce static charges developed during extrusion, conversion in
later processing, and end-use such as with the consumer product),
scavengers and absorbers (to absorb odors and gaseous compound such
as from the film and/or the packaged product), odor enhancers (to
impart a desirable odor to the subsequently-formed film),
degradation agents (to increase polymer break-down during disposal
in landfills), and so on.
[0143] Processing aids may be added to improve the extrusion
characteristics of a polymer by facilitating lower extrusion
pressures or reducing melt fracture, for instance. Examples of
processing aids are flow promoters which may lubricated the metal
surface in which the molten polymer contacts, reducing drag and
thus reducing melt fracture and other theological-induced surface
imperfections. Flow promoters can also reduce extrusion power
consumption, and build-up or accumulation of polymer at the
extrusion die. Flow promoters in polyethylene resin extrusion may
include fluoroelastomers (which reduce melt fracture and improves
resin processability), polyethylene glycol, and low molecular
weight PE waxes, and so forth.
[0144] In general, the extruder 356 may melt, homogenize, and pump
the polyolefin polymer and additives through a pelletizer 358,
which may include a screen pack and heated die head, for example,
which pelletizes the mixture of fluff and additives. Further,
pelletizer knife blades (i.e., under water) may cut the polyolefin
melt extruded through the die into pellets. The pellets are
typically quenched by water 360 and may travel in a pellet-water
slurry 362 from the pelletizer 358 to a pellet dewatering dryer
364. The dryer 364 may separate the free water and then dry the
remaining surface water from the pellets by centrifugal force. The
dried pellets 366 may discharge onto a scalping screen 368, for
example, which removes oversized and undersized pellets from
on-specification pellets 370.
[0145] Water 360 may be supplied to the pelletizer 358 from a water
tank 372 via a centrifugal pump 374 and cooler 376 (e.g., shell and
tube heat exchanger). Water 378 removed from the pellet dryer 364
may return to the water tank 372. The polyolefin pellets 370
exiting the scalping screen 368 may fall by gravity through a
rotary valve 380 into a dense-phase pneumatic conveying line 382,
for example, and transported to pellet silos 384. A blower package
386 provides nitrogen and/or air 388 to convey the pellets 370 via
conveying line 382 to the pellet silos 384. In certain examples,
the pellet silos 384 may be characterized as the interface of
between the extrusion system 36 and the loadout system 39, as
components of the extrusion 36 and/or loadout system 39, and the
like.
[0146] The pellet silos 384 may include storage tanks, blenders,
off-specification storage tanks, and so on. The polyolefin pellets
390 may be loaded into rail cars 392, hopper cars, trucks, tote
bins, bags, and so on. Pellets 390 may be loaded into hopper cars,
for example, using a gravity type, air assisted, multiple-spout,
loading system. Such a system may allow the hopper car to be
automatically loaded at a rate higher than the polymerization and
extrusion production rate. Thus, extra "time" generated by the
higher loadout rates may be exploited to provide time to move the
hopper cars or rail cars 392 after filling, and to spot the next
empty car 392.
[0147] FIGS. 15A-15C depict exemplary embodiments of portions of
two extrusion systems 36-1 and 36-2 including respective extruder
feed tanks 348-1 and 348-2 and respective extruders 356-1 and
356-2. The extruder feed tank 348-1 receives treated fluff solids
28-1 from a monomer/diluent recovery system 24-1. The extruder feed
tank 348-2 receives treated fluff solids 28-2 from a
monomer/diluent recovery system 24-2. FIG. 15A in analogous to FIG.
16 in that the first extruder feed tank 348-1 feeds fluff 354-1 to
the first extruder 356-1, and the second extruder feed tank 348-2
feeds fluff 354-2 to the second extruder 356-2.
[0148] The alternate embodiments of FIGS. 15B and 15C provide
capability to combine the treated fluff solids 28-1 and 28-2 to the
extruder 256-2. Thus, if desired, the extruder 356-1 may be taken
offline for inspection or maintenance, and/or the fluff solids 28-1
and 28-2 combined for inclusion of the same additive package, for
example. The embodiment in FIG. 15C also provides the capability to
divide the treated fluff solids 28-1 between the two extruders
256-1 and 256-2, such as when desired to incorporate two different
additive packages via parallel pelletizing of split streams of the
fluff solids 28-1.
[0149] In FIG. 15B, the first extruder feed tank 348-1 may feed
fluff 354-1 to the first extruder 356-1 or the second extruder
356-2. A diverter or 3-way valve 400 diverts the fluff 354-1 from
the first extruder feed tank 348-1 to either the first extruder
356-1 or the second extruder 356-2. As for the second extruder feed
tank 348-2, it feeds fluff 354-2 to the second extruder 356-2.
Thus, in this example, the treated fluff solids 28-1 from a
monomer/diluent recovery system 24-1 may be fed to extruder 356-1
or to extruder 356-2.
[0150] FIG. 15C depicts the capability for the first extruder feed
tank 348-1 to feed fluff 354-1A through a level control valve 402
to the first extruder 356-1 and to feed fluff 354-1B through a
level control valve 404 to the second extruder 356-2. In operation,
the fluff 354-1A and 354-1B streams may flow simultaneously, with
both control valves 402 and 404 operating to maintain a fluff level
in the extruder feed tank 348-1. On the other hand, one of the
control valves 402 and 404 may be closed such that only one of the
fluff 354-1A and 354-1B streams flow. As for the second extruder
feed tank 348-2, it feeds fluff 354-2 to the second extruder 356-2.
Thus, in this example, the treated fluff solids 28-1 from a
monomer/diluent recovery system 24-1 may be fed to only extruder
356-1, fed to only to extruder 356-2, or split and fed to both
extruder 356-1 and 356-2 at the same time.
[0151] In summary, embodiments of the present techniques may
provide for a polyolefin production system including: a first
reactor (e.g., loop reactor) configured to produce a first reactor
discharge having a first polyolefin (e.g., polyethylene); a second
reactor (e.g., loop reactor) configured to produce a second reactor
discharge comprising a second polyolefin (e.g. polyethylene); and a
post-reactor treatment zone configured to receive the first reactor
discharge and the second reactor discharge, wherein the first and
second reactors are configured to allow the first reactor discharge
to be (a) transferred to the second reactor and, alternatively. (b)
diverted to by-pass the second reactor and fed into the
post-reactor treatment zone wherein the first and second
polyolefins are first contacted in the post-reactor treatment zone.
The first polyolefin may have a higher average molecular weight
than the second polyolefin, or the second polyolefin has a higher
average molecular weight than the first polyolefin. Further, the
first polyolefin and the second polyolefin may have different
densities. Moreover, the first polyolefin may be 30 weight % to 70
weight % of the second polyolefin. The post-reactor treatment zone
may include a separation vessel, purge column, extruder feed tank,
extruder, and so on. The first and second polyolefins may be
transferred to the post-reactor treatment zone such that the first
and second polyolefins are first contacted in the separation
vessel, purge column, extruder feed tank, or extruder, and the
like.
[0152] Further, embodiments of the present techniques may provide a
polyolefin production system including a first-reactor to produce a
first reactor discharge having polyolefin and non-polyolefin
components, and a post-reactor treatment zone to receive the first
reactor discharge and produce a first extruded polyolefin and a
second extruded polyolefin. The post-reactor treatment zone may
include a separation vessel configured to receive the first reactor
discharge and produce first and second separation-vessel product
streams. The post-reactor treatment zone may include a separation
vessel and a purge column, wherein the separation vessel receives
the first reactor discharge and produces a separation-vessel
product stream, and the purge column receives the separation-vessel
product stream and produces first and second purge-column product
streams. The post-reactor treatment zone may include a separation
vessel, a purge column, and an extruder feed tank. In this example,
the separation vessel receives the first reactor discharge and
produces a separation-vessel product stream, the purge column
receives the separation-vessel product stream and produces a
purge-column product stream, and the extruder feed receives the
purge-column product stream and produce first and second
extruder-tank product streams.
[0153] In certain examples, a second reactor produces a second
reactor discharge which is fed into the first reactor. Thus, in
these examples, the initial reactor in series is labeled as the
second reactor. The polyolefin in the second reactor discharge may
have a higher or lower average molecular weight than polyolefin in
the first reactor discharge. Further, polyolefin in the second
reactor discharge may have a different density than polyolefin in
the first reactor discharge. Polyolefin in the second reactor
discharge may be 30 weight % to 70 weight % of polyolefin in the
second reactor discharge. Moreover, the first extruded polyolefin
and the second extruded polyolefin may have different additive
packages. The different additive packages may include surface
modifiers, UV inhibitors, antioxidants, colorants, pigments, or any
combination thereof.
[0154] Lastly, embodiments of the present techniques may provide a
polyolefin production system including: a first reactor to produce
a first discharge slurry having a first polyolefin; a second
reactor to produce a second discharge slurry having a second
polyolefin; and a post-reactor treatment zone having a separation
vessel configured to receive as separate feeds the first discharge
slurry and the second discharge slurry in certain operating modes.
The first and second reactors may be configured to allow the first
discharge slurry to be (a) transferred to the second reactor and,
alternatively, (b) diverted to by-pass the second reactor and fed
into the post-reactor treatment zone. In embodiments, the first
discharge slurry and the second discharge slurry initially meet in
the separation vessel, and do not meet upstream of the separation
vessel. In certain examples, the first discharge slurry and the
second discharge slurry do not initially meet in a conduit but
first meet in a vessel, such as the separation vessel or other
vessel, i.e., with the vessel having two inlets to receive
respectively the first discharge slurry and the second discharge
slurry.
[0155] The post-reactor treatment zone may include the separation
vessel, a purge column, an extruder feed tank, and an extruder, and
so forth. Of course, alternate configurations are applicable. The
first and second polyolefins may be transferred to the s
post-reactor treatment zone such that the first and second
polyolefins initially meet in the separation vessel, purge column,
extruder feed tank, or extruder, etc. Some embodiments also provide
that the first and second polyolefins may meet in the inlet piping
of the purge column, inlet piping of the extruder feed tank, and
inlet piping of the extruder, but not in inlet piping of the
separation vessel (e.g., flash vessel). As indicated, the first
polyolefin may have a higher or lower average molecular weight than
the second polyolefin, and a different density than the second
polyolefin. The first polyolefin may be 30 weight % to 70 weight %
of the second polyolefin.
ADDITIONAL DESCRIPTION
[0156] A polyolefin production system has been described. The
following clauses are offered as further description:
Embodiment A
[0157] A polyolefin production system comprising: a first reactor
configured to produce a first reactor discharge comprising a first
polyolefin; a second reactor configured to produce a second reactor
discharge comprising a second polyolefin; a post-reactor treatment
zone configured to receive the first reactor discharge and the
second reactor discharge, wherein the first and second reactors are
configured to allow the first reactor discharge to be (a)
transferred to the second reactor and, alternatively, (b) diverted
to by-pass the second reactor and fed into the post-reactor
treatment zone wherein the first and second polyolefins are first
contacted in the post-reactor treatment zone.
Embodiment B
[0158] The polyolefin production system of embodiment A, wherein
the first reactor and the second reactor each comprise a loop
reactor.
Embodiment C
[0159] The polyolefin production system of embodiments A through B,
wherein: the post-reactor treatment zone comprises a separation
vessel; and the first and second polyolefins are transferred to the
pressure separation vessel such that the first and second
polyolefins are first contacted in the separation vessel.
Embodiment D
[0160] The polyolefin production system of embodiments A through C,
wherein: the post-reactor treatment zone comprises a purge column;
and the first and second polyolefins are transferred to the purge
column such that the first and second polyolefins are first
contacted in the purge column.
Embodiment E
[0161] The polyolefin production system of embodiments A through D,
wherein: the post-reactor treatment zone comprises an extruder feed
tank; and the first and second polyolefins are transferred to the
extruder feed tank such that the first and second polyolefins are
first contacted in the extruder feed tank.
Embodiment F
[0162] The polyolefin production system of embodiments A through E,
wherein: the post-reactor treatment zone comprises an extruder; and
the first and second polyolefins are transferred to the extruder
such that the first and second polyolefins are first contacted at
the inlet of and blended in the extruder.
Embodiment G
[0163] The polyolefin production system of embodiments A through F,
wherein the first and second polyolefins are polyethylene.
Embodiment H
[0164] The polyolefin production system of embodiments A through G,
wherein the first polyolefin has a higher average molecular weight
than the second polyolefin.
Embodiment I
[0165] The polyolefin production system of embodiments A through H,
wherein the second polyolefin has a higher average molecular weight
than the first polyolefin.
Embodiment J
[0166] The polyolefin production system of embodiments A through I,
wherein the first polyolefin has a different density than the
second polyolefin.
Embodiment K
[0167] The polyolefin production system of embodiments A through J,
wherein the first polyolefin is 30 weight % to 70 weight % of the
second polyolefin.
Embodiment L
[0168] The polyolefin production system of embodiments A through K,
wherein the post-reactor treatment zone comprises an extruder feed
tank and an extruder, and wherein performance additives are added
into at least one of the extruder feed tank or the extruder.
Embodiment M
[0169] A polyolefin production system comprising: a first-reactor
configured to produce a first reactor discharge comprising
polyolefin and non-polyolefin components: and a post-reactor
treatment zone configured to receive the first reactor discharge
and produce a first extruded polyolefin and a second extruded
polyolefin.
Embodiment N
[0170] The polyolefin production system of embodiment M, wherein
the post-reactor treatment zone comprises a separation vessel
configured to receive the first reactor discharge and produce first
and second separation-vessel product streams.
Embodiment O
[0171] The polyolefin production system of embodiments M through N,
wherein: the post-reactor treatment zone comprises a separation
vessel and a purge column, wherein: the separation vessel is
configured to receive the first reactor discharge and produce a
separation-vessel product stream, and the purge column is
configured to receive the separation-vessel product stream and
produce first and second purge-column product streams.
Embodiment P
[0172] The polyolefin production system of embodiments M through O,
wherein: the post-reactor treatment zone comprises a separation
vessel, a purge column, and an extruder feed tank; the separation
vessel is configured to receive the first reactor discharge and
produce a separation-vessel product stream, the purge column is
configured to receive the separation-vessel product stream and
produce a purge-column product stream, and the extruder feed tank
is configured to receive the purge-column product stream and
produce first and second extruder-tank product streams.
Embodiment O
[0173] The polyolefin production system of embodiments M through P,
further comprising a second reactor configured to produce a second
reactor discharge which is fed into the first reactor.
Embodiment R
[0174] The polyolefin production system of embodiments M through Q,
wherein polyolefin in the second reactor discharge has a higher
average molecular weight than polyolefin in the first reactor
discharge.
Embodiment S
[0175] The polyolefin production system of embodiments M through R,
wherein polyolefin the first reactor discharge has a higher average
molecular weight than polyolefin the second reactor discharge.
Embodiment T
[0176] The polyoletin production system of embodiments M through S,
wherein polyolefin in the second reactor discharge has a different
density than polyolefin in the first reactor discharge.
Embodiment U
[0177] The polyolefin production system of embodiments M through T,
wherein polyolefin in the second reactor discharge is 30 weight %
to 70 weight % of polyolefin in the second reactor discharge.
Embodiment V
[0178] The polyolefin production system of embodiments M through U,
wherein the first extruded polyolefin and the second extruded
polyolefin comprise different additive packages
Embodiment W
[0179] The polyolefin production system of embodiments M through V,
wherein the different additive packages comprise surface modifiers,
UV inhibitors, antioxidants, colorants, pigments, or any
combination thereof.
Embodiment X
[0180] A polyolefin production system comprising: a first reactor
configured to produce a first discharge slurry comprising a first
polyolefin; a second reactor configured to produce a second
discharge slurry comprising a second polyolefin; and a post-reactor
treatment zone comprising a separation vessel configured to receive
as separate feeds the first discharge slurry and the second
discharge slurry.
Embodiment Y
[0181] The polyolefin production system of embodiment X, wherein
the first and second reactors are configured to allow the first
discharge slurry to be (a) transferred to the second reactor and,
alternatively. (b) diverted to by-pass the second reactor and fed
into the post-reactor treatment zone.
Embodiment Z
[0182] The polyolefin production system of embodiments X through Y,
wherein the first discharge slurry and the second discharge slurry
initially meet in the separation vessel.
Embodiment AA
[0183] The polyolefin production system of embodiments X through Z,
wherein the first discharge slurry and the second discharge slurry
do not meet upstream of the separation vessel.
Embodiment AB
[0184] The polyolefin production system of embodiments X through
AA, wherein the first discharge slurry and the second discharge
slurry do not initially meet in a conduit.
Embodiment AC
[0185] The polyolefin production system of embodiments X through
AB, wherein the first and second polyolefins are transferred to the
separation vessel such that the first and second polyolefins
initially meet in the separation vessel.
Embodiment AD
[0186] The polyolefin production system of embodiments X through
AC, wherein: the post-reactor treatment zone comprises a purge
column: and the first and second polyolefins are transferred to the
purge column such that the first and second polyolefins initially
meet in inlet piping of the purge column or in the purge
column.
Embodiment AE
[0187] The polyolefin production system of embodiments X through
AD, wherein: the post-reactor treatment zone comprises an extruder
feed tank; and the first and second polyolefins are transferred to
the extruder feed tank such that the first and second polyolefins
initially meet in inlet piping of the extruder feed tank or in the
extruder feed tank.
Embodiment AF
[0188] The polyolefin production system of embodiments X through
AE, wherein: the post-reactor treatment zone comprises an extruder;
and the first and second polyolefins are transferred to the
extruder such that the first and second polyolefins initially meet
in inlet piping of the extruder or in the extruder, and are blended
in the extruder.
Embodiment AG
[0189] The polyolefin production system of embodiments X through
AF, wherein the first polyolefin has a higher average molecular
weight than the second polyolefin.
Embodiment AH
[0190] The polyolefin production system of embodiments X through
AG, wherein the second polyolefin has a higher average molecular
weight than the first polyolefin.
Embodiment AI
[0191] The polyolefin production system of embodiments X through
A-H, wherein the first polyolefin has a different density than the
second polyolefin.
Embodiment AJ
[0192] The polyolefin production system of embodiments X through
AI, wherein the first polyolefin is 30 weight % to 70 weight % of
the second polyolefin.
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