JP5237258B2 - 直列に配置された複数の反応装置を用いてエチレンのポリマーを製造する方法 - Google Patents
直列に配置された複数の反応装置を用いてエチレンのポリマーを製造する方法 Download PDFInfo
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- JP5237258B2 JP5237258B2 JP2009502090A JP2009502090A JP5237258B2 JP 5237258 B2 JP5237258 B2 JP 5237258B2 JP 2009502090 A JP2009502090 A JP 2009502090A JP 2009502090 A JP2009502090 A JP 2009502090A JP 5237258 B2 JP5237258 B2 JP 5237258B2
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Classifications
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
- C08F210/16—Copolymers of ethene with alpha-alkenes, e.g. EP rubbers
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F2/00—Processes of polymerisation
- C08F2/12—Polymerisation in non-solvents
- C08F2/14—Organic medium
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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- C08F4/44—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides
- C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
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- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
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- C08F4/60—Metals; Metal hydrides; Metallo-organic compounds; Use thereof as catalyst precursors selected from light metals, zinc, cadmium, mercury, copper, silver, gold, boron, gallium, indium, thallium, rare earths or actinides together with refractory metals, iron group metals, platinum group metals, manganese, rhenium technetium or compounds thereof
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Description
本発明は特に、触媒と助触媒とを第1反応装置に注入し、追加の共触媒は少なくとも一つの自段の反応装置に注入する方法に関するものである。例えば、本発明方法は液体が充填された2つのループ反応装置から成るダブルループ重合反応装置に適用できる。第1と第2の反応装置は第1反応装置に設けた1つまたは複数の沈澱レグを介して互いに直列に連結され、スラリーは沈澱レグを介して第1反応装置から前記第2反応装置へ排出される。直列に連結された反応装置は特にビモダルな(双峰の)ポリエチレン(PE)の製造に適している。
下記文献にはスラリー重合と気相重合とを組合せてビモダルなポリエチレンを製造する方法が記載されている。
「オフガス、off gas」とは未重合のエチレンと未重合のコモノマー(水素および不溶気体を含むこともある)の反応装置からのパージガスを意味する。「オフガス」が減少するということは第2反応装置中の触媒活性が良いということを意味する。すなわち、反応装置の能力を変えずに、触媒消費量が減少する。換言すれば、生産性性が向上する。
下記文献には、メルトインデックスMI2が5〜1000g/10分のポリマーと、メルトインデックスMI5が0.01〜2g/10分のポリマーとから成るエチレンのポリマーを含む組成物の製造方法が記載されている。
(a)第1反応装置中にエチレン、希釈剤、触媒、助触媒および任意成分のコモノマーおよび水素を導入し、
(b)第1反応装置の反応混合物中で、エチレンおよび任意成分のコモノマーを重合してエチレンのポリマーを作り、
(c)第1反応装置から反応混合物を排出し、
(d)反応混合物と、新たなエチレンと、任意成分のコモノマーおよび水素とを下段の反応装置中に導入して、追加のエチレンのポリマーを作り、
(e)下段の反応装置から反応混合物を排出し、さらに下段の反応装置がある場合にはその反応装置中に、新たなエチレンと、任意成分のコモノマーおよび水素と一緒に導入して、追加のエチレンのポリマーを作り、
(c)と(d)の階段を直列に配列した最後の反応装置まで繰返し、
(f)直列に配列した最後の反応装置から反応混合物を排出し、エチレンのポリマーを回収する、
を有する、直列に並べられた複数の反応装置を使用してエチレンのポリマーを製造する方法において、
直列に配列した少なくとも一つの反応装置に追加の助触媒を注入することを特徴とする方法を提供する。
本発明の好ましい実施例は直列に接続した2つの反応装置のみから成る。他の好ましい実施例では直列に配列した反応装置の少なくとも1つはループ反応装置である。他の実施例では全ての反応装置がループ反応装置である。他の実施例では、直列な全ての反応装置で重合をスラリー条件で行い、エチレンのポリマーは固体粒子から成り、希釈剤中に懸濁するのが有利である。他の実施例では、反応装置のスラリー含有物をポンプで連続的に循環して、液体希釈剤中のポリマー固体粒子の効率的な懸濁液を維持する。他の実施例では、反応装置は液体を一杯に充填したループ反応装置である。本発明方法は上記の実施例の少なくとも2つの任意の組合せから成ることができる。
本発明方法の効果は、主として同じポリエチレンを製造する場合に、触媒の消費量を減少させることができるテン、換言すれば、生産性が向上する(生産性とは触媒1g当りのポリエチレンのg数)。
(a)第1反応装置中にエチレン、希釈剤、触媒、助触媒および任意成分のコモノマーおよび水素を導入し、
(b)第1反応装置の反応混合物中で、エチレンおよび任意成分のコモノマーを重合してエチレンのポリマーを作り、
(c)第1反応装置から反応混合物を排出し、
(d)反応混合物と、新たなエチレンと、任意成分のコモノマーおよび水素とを下段の反応装置中に導入して、追加のエチレンのポリマーを作り、
(e)下段の反応装置から反応混合物を排出し、さらに下段の反応装置がある場合にはその反応装置中に、新たなエチレンと、任意成分のコモノマーおよび水素と一緒に導入して、追加のエチレンのポリマーを作り、
(c)と(d)の階段を直列に配列した最後の反応装置まで繰返し、
(f)直列に配列した最後の反応装置から反応混合物を排出し、エチレンのポリマーを回収する、
を有する、直列に並べられた複数の反応装置を使用してエチレンのポリマーを製造する方法において、
直列に配列した少なくとも一つの反応装置に追加の助触媒を注入し、注入する触媒の量を減し且つ直列に配列した反応装置の生産能力を変えないことを特徴とする改良方法にも関するものである。
一般に:メタロセン触媒は固体担体に担持される。担体は不活性な固形物でなければならず、従来のメタロセン触媒の成分のいずれとも化学的に不活性でなければならない。好ましい担体はシリカ化合物である。
本発明では共触媒として周期律表の第I〜III族有機金属化合物が好ましく使われる。特に好ましい助触媒例の例はメタロセン触媒と一緒に使用するのに適した触媒で、ハロゲン化されていてもよい有機アルミニウム化合物で、一般式AlR3またはAlR2Yを有する。ここで、Rは1〜16の炭素原子を有するアルキルであり、各Rは互いに同じものでも異なっていてもよく、Yは水素またはハロゲンである。触媒の例はトリメチルアルミニウム、トリエチルアルミニウム、ジイソブチルアルミニウム水素化物、トリ-イソブチルアルミニウム、トリヘキシルアルミニウム、ジエチル塩化アルミニウムまたはジエチルアルミニウムエトキシドであるが、これらに限られるものではない。本発明で用いるのに特に好ましい助触媒はトリ-イソブチルアルミニウムである。
適した不活性希釈剤(溶剤またはモノマーとは逆)は公知で反応条件下で不活性であるか少なくとも本質的に不活性で液体である炭化水素である。好ましい適当な炭化水素はイソブタン、n-ブタン、プロパン、n−ペンタン、イソペンタン、ネオペンタン、イソヘキサンおよびn−ヘキサンであり、イソブタンが好ましい。
実施例1: 比較例(第2反応装置へのTibalの噴射なし)
実施例2: 第2反応装置中へTibal噴射。
触媒はチーグラー−ナッタである。
第1反応装置の触媒供給ラインを介して第1反応装置にTibal(トリイソブチルアルミニウム)を注入した。触媒と助触媒との間の前接触時間は短い。第2反応装置にはTibalを直接注入した。第2反応装置に加えたTibalの濃度は第2反応装置に注入した新しい(フレッシュな)イソブタンを基にした量である。活性および生産性は下記の式で計算した:
反応装置1の活性 [g/g/時/%C2]=反応装置1の生産性[g/g]/(滞在時間[時]*C2 OG [%])
C2 OGはオフガス中のエチレン濃度を意味する。
滞在時間[時]=(反応装置体積[m3]*dスラリー[kg/m3]*固形物)/PE流量[kg/時]
反応装置2も同じ。生産性は触媒1g当りのポリエチレンのg数である。
Claims (8)
- 下記の(a)〜(f)の段階:
(a)第1反応装置中にエチレン、希釈剤、触媒、助触媒および任意成分のコモノマーおよび水素を導入し、
(b)第1反応装置の反応混合物中で、エチレンおよび任意成分のコモノマーを重合してエチレンのポリマーを作り、
(c)第1反応装置から反応混合物を排出し、
(d)反応混合物と、新たなエチレンと、任意成分のコモノマーおよび水素とを下段の反応装置中に導入して、追加のエチレンのポリマーを作り、
(e)下段の反応装置から反応混合物を排出し、さらに下段の反応装置がある場合にはその反応装置中に、新たなエチレンと、任意成分のコモノマーおよび水素と一緒に導入して、追加のエチレンのポリマーを作り、
(c)と(d)の階段を直列に配列した最後の反応装置まで繰返し、
(f)直列に配列した最後の反応装置から反応混合物を排出し、エチレンのポリマーを回収する、
を有する、直列に並べられた複数の反応装置を使用してエチレンのポリマーを製造する方法において、
直列に配列した反応装置の少なくとも一つがループ反応装置であり、直列に配列した少なくとも一つの下段の反応装置に追加の助触媒を注入し、この下段の反応装置に注入する追加の助触媒の濃度を0.1X〜Xの間にする(ここで、Xは第1の反応装置に注入された新しい希釈剤の量を元にした濃度)ことを特徴とする方法。 - 直列に配列した2つの反応装置のみを有する請求項1に記載の方法。
- 全ての反応装置がループ反応装置である請求項1または2に記載の方法。
- 直列に配列した全ての反応装置で重合がスラリー条件下に実行される請求項1〜3のいずれか一項に記載の方法。
- エチレンのポリマーが固体粒子から成り、希釈剤中に懸濁している請求項4に記載の方法。
- 希釈剤が不活性な希釈剤である請求項4または5に記載の方法。
- 反応装置のスラリー含有物をポンプによって連続的に循環してポリマーの固体粒子を液体希釈剤中に懸濁状態に維持する請求項4または5に記載の方法。
- 反応装置が液体が一杯に充填されたループ反応装置である請求項3〜7のいずれか一項に記載の方法。
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EP06112030A EP1847554A1 (en) | 2006-03-30 | 2006-03-30 | Slurry polymerisation process of ethylene in the presence of low amount of scavenger |
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EP06121494.6 | 2006-09-29 | ||
EP06121494A EP1905785A1 (en) | 2006-09-29 | 2006-09-29 | Process for the preparation of ethylene polymers using a number of reactors arranged in series |
PCT/EP2007/053028 WO2007113208A1 (en) | 2006-03-30 | 2007-03-29 | Process for the preparation of ethylene polymers using a number of reactors arranged in series |
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EP1905785A1 (en) | 2006-09-29 | 2008-04-02 | Total Petrochemicals Research Feluy | Process for the preparation of ethylene polymers using a number of reactors arranged in series |
EP1842861A1 (en) * | 2006-04-03 | 2007-10-10 | Total Petrochemicals Research Feluy | Process for improving the polymerization of ethylene and one or more optional comonomer(s) in a polymerization loop reactor. |
EP2033976A1 (en) * | 2007-09-03 | 2009-03-11 | INEOS Manufacturing Belgium NV | Slurry phase polymerisation process |
US20100125124A1 (en) * | 2008-11-17 | 2010-05-20 | Fina Technology, Inc. | Methods of catalyst activation |
JP5837424B2 (ja) * | 2009-02-27 | 2015-12-24 | バーゼル・ポリオレフィン・ゲーエムベーハー | エチレンを重合するための多段階方法 |
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