Method for activation of chromium containing catalyst precursor for polymerization and the resulting polymerization catalyst

• US 9,266,976 B2
• Filed: 11/29/2011
• Issued: 02/23/2016
• Est. Priority Date: 11/30/2010
• Status: Active Grant

• Current Assignee: Basell Polyolefine GmbH (Lyondellbasell Industries NV)
• Original Assignee: Basell Polyolefine GmbH (Lyondellbasell Industries NV)
• Inventors: Hecker, Manfred, De Lange, Paulus, Karer, Rainer
• Primary Examiner(s): Zimmer, Anthony J
• Application Number:
  US13/990,490
• Publication Number:
  US 20130252809A1
• Time in Patent Office: 1,547 Days
• Field of Search: 502/319
• US Class Current: 1/1
• CPC Class Codes: B01J 23/26 Chromium
• CPC Class Codes: B01J 37/14 with gases containing free oxygen
• CPC Class Codes: B01J 38/14 with control of oxygen content in oxidation gas
• CPC Class Codes: B01J 38/30 in gaseous suspension, e.g. fluidised bed
• CPC Class Codes: B01J 38/32 Indirectly heating or cooling material within regeneration zone or prior to entry into regeneration zone
• 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 4/24 Oxides
• CPC Class Codes: C08F 4/69 Chromium, molybdenum, tungsten or compounds thereof
• CPC Class Codes: Y02P 20/584 Recycling of catalysts

Abstract

The instant invention relates to an activation of a polymerization catalyst precursor by heat treatment comprising a support material and a catalyst precursor deposited thereon in a fluidized bed activator and to the use of the activated polymerization catalyst in the manufacture of polyolefins. The activation involves heat treatment in the presence of oxygen. After that activation the oxygen in the activator is replaced by inert gas via flushing until the fluidization gas emerging from the activator comprises oxygen in a maximum amount of up to 5 ppm. The catalyst prepared by that method is improved with respect to prevent reactor fouling during gas-phase polymerization or slurry polymerization either in stirred vessel or loop.

Claims

1. A method comprising:

preparing a Cr-containing polymerization catalyst by

heat-treating a chromium catalyst precursor in a fluidized-bed method, wherein the heat treatment step is performed in an activator in the presence of oxygen at a temperature in the range of from 300 to 1000°

C. over a time period of from 0.5 to 48 h,

wherein after the heat-treating step the oxygen in the activator is replaced by an inert gas during a cooling period and thereafter via flushing until a fluidization gas emerging from the activator comprises oxygen in an amount up to 5 ppm and wherein the fluidization gas emerging from the activator is controlled by an oxygen detection by means of an oxygen detector arranged behind a fluidization gas outlet.

2. The method of claim 1, wherein air is used as an oxygen source to oxidize Cr(III) to Cr(VI).

3. The method of claim 1, wherein the heat-treating step is performed in a cylindrical activator arranged vertically comprising tubular activator walls, a fluidization gas inlet near the bottom, a fluidization gas outlet near the top and a heat exchange jacket outside the tubular activator walls, wherein the fluidization gas emerging the reactor during the cooling period is subjected to oxygen detection by means of an oxygen detector arranged behind the fluidization gas outlet on top of the activator.

4. The method of claim 1, further comprising polymerizing at least one olefin in the presence of the Cr-containing polymerization catalyst, wherein the Cr-containing polymerization catalyst does not produce reactor fouling during the polymerizing step.

5. The method of claim 4, wherein the polymerizing step is a gas-phase polymerization or a slurry polymerization in stirred vessel or loop.

6. The method of claim 4, wherein the at least one olefin is ethylene, propylene, butene, pentene, hexane, or mixtures thereof.