Process and apparatus for the gas-phase polymerization of α-olefins

• US 6,413,477 B1
• Filed: 10/03/1997
• Issued: 07/02/2002
• Est. Priority Date: 07/20/1995
• Status: Expired due to Term

• Current Assignee: Basell Poliolefine Italia Srl (Lyondellbasell Industries NV)
• Original Assignee: Basell Technology Company BV
• Inventors: Rinaldi, Roberto, Covezzi, Massimo, Govoni, Gabriele, Galli, Paolo
• Primary Examiner(s): TRAN, HIEN THI
• Application Number:
  US08/943,748
• Time in Patent Office: 1,733 Days
• Field of Search: 422/131-132, 422/139, 422/140-142, 422/143, 422/147, 422/189, 422/234-235, 422/145, 526/65, 526/352, 526/901, 526/904, 526/905, 525/53
• US Class Current: 422/131
• CPC Class Codes: B01J 19/2435 Loop-type reactors
• CPC Class Codes: B01J 8/1863 followed by a downward movement outside the reactor and subsequently re-entering it
• CPC Class Codes: B01J 8/388 externally, i.e. the particles leaving the vessel and subsequently re-entering it
• CPC Class Codes: C08F 10/00 Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
• CPC Class Codes: C08F 110/06 Propene
• CPC Class Codes: C08F 2/001 Multistage polymerisation processes characterised by a change in reactor conditions without deactivating the intermediate polymer C08F295/00, C08F297/00 take precedence
• CPC Class Codes: C08F 2/34 Polymerisation in gaseous state
• CPC Class Codes: C08F 210/14 Monomers containing five or more carbon atoms
• CPC Class Codes: C08F 210/16 Copolymers of ethene with alpha-alkenes, e.g. EP rubbers
• CPC Class Codes: C08F 2500/08 Low density, i.e. < 0.91 g/cm3
• CPC Class Codes: C08F 2500/12 Melt flow index or melt flow ratio
• CPC Class Codes: C08F 2500/18 Bulk density
• CPC Class Codes: Y10S 526/901 Monomer polymerized in vapor state in presence of transition metal containing catalyst

Abstract

Process for gas-phase polymerization carried out in two interconnected polymerization zones, to which one or more α-olefins CH₂═CHR are fed in the presence of catalyst under reaction conditions and from which the polymer product is discharged. The process is characterized in that the growing polymer flows through a first polymerization zone under fast fluidization conditions, leaves said first zone and enters a second polymerization zone through which it flows in a densified form under the action of gravity, leaves said second zone and is reintroduced into the first polymerization zone, thus establishing a circulation of polymer around the two polymerization zones. The novel process allows olefins to be polymerized in the gas phase with high productivity per unit volume of the reactor without incurring the problems of the fluidized-bed technologies of the known state of the art.

Claims

1. Apparatus for the gas-phase polymerization of α

-olefins, comprising;

a first vertical cylindrical reactor equipped with a catalyst feedline; and

a second vertical cylindrical reactor equipped with a polymer discharge system;

the upper region of said first reactor being connected by a first line to an inlet of a solid/gas separator which is in turn connected by its outlet for the solid to the upper region of said second reactor;

the lower region of said second reactor being connected by a second line to the lower region of said first reactor; and

said solid/gas separator being connected by means of a recirculation line for the gaseous mixture that enters said first reactor in a region at the bottom of said first reactor below and separate from the point of entry of said second line to the first reactor.

2. Apparatus according to claim 1, wherein said first reactor is equipped with gas distributor means located between the point of entry of said second line and said region at the bottom of said first reactor.

3. Apparatus according to claim 1, wherein a first control valve for controlling the polymer flow rate is interposed between said second reactor and said second line.

4. Apparatus according to claim 3, wherein said first valve is a mechanical valve.

5. Apparatus according to claim 3, wherein said first valve is a non-mechanical valve.

6. Apparatus according to claim 2, wherein said catalyst feedline is connected via a third line to said first reactor at a point above said gas distributor means.

7. Apparatus according to claim 1, wherein said recirculation line for the gaseous mixture is equipped with a compressor, a cooling system and systems for introducing monomers and molecular weight regulator.

8. Apparatus according to claim 1, wherein said first line leaves the upper region of said first reactor laterally.

9. Apparatus according to claim 1, wherein the upper region of said first reactor is of frustoconical geometry so that the end of larger diameter is oriented above the end of smaller diameter.

10. Apparatus according to claim 7, wherein said recirculation line for the gaseous mixture is connected, at a point downstream of said compressor, via a line to said second line.

11. Apparatus according to claim 1, wherein said first reactor is equipped with external cooling means.