SA93140029B1 - Process for polymerizing monomers in fluidized bed - Google Patents

Abstract

Abstract: The invention is directed toward the polymerizing or copolymerizing of alpha-olefins either alone or in combination with one or more other alpha-olefins, in a gas-phase reactor comprising a fluidized bed and a fluidizing medium, such that the fluidizing medium enters the reactor Gas and liquid phase.

Description

PROCESS FOR POLYMERizing MONOMETS IN FLUIDIED BED BACKGROUND : FULL DESCRIPTION BACKGROUND : Z The present invention relates to a process for the polymerization of gas phase olefins of olefins in fluidized bed reactors. The present invention enables significant savings in energy and capital cost by significantly increasing the polymer production capacity at a reactor capacity rate of > ° given volume. The discovery of the process for producing polymers in aT gee layers provided a way to produce a variety of polymers. The use of a gas fluidized bed polymerization process significantly reduces energy requirements compared to other processes and reduces; in the manner of: more important; Capital investment required to conduct this process. 1 Bale uses continuous cycle gas fluidized bed polymerization plants. A gas stream is heated for part of the cycle; circulating in a reactor; polymerization temperature. This heat is removed in another part of the cycle by a cooling system outside the reactor. It usually bears fruit in a gas layer process dal ee to produce polymers from monomers by passing a gaseous stream containing one or more monomers; continuously; through a ve fluidized bed under activating conditions and in the presence of a catalyst. This gaseous stream was withdrawn from the fluidized bed and returned back to the reactor. At the same time the polymer product is withdrawn from the reactor and a new monomer is added to replace the polymerized monomer. .. It is important that the heat generated by the reaction be removed in order to maintain the temperature of the gaseous stream inside the reactor at a temperature lower than the temperatures of the polymer and catalyst vexation. It is also important to prevent agglomeration or the formation of thick pieces.

of a polymer that cannot be displaced as a product. This is done by controlling the temperature of the gaseous stream in the reaction bed at a temperature below the temperature of fusion or adhesion of the polymer particles produced during the polymerization reaction. Thus, it is understood that the amount of polymer produced in a fluidized bed polymerization process is directly proportional to the amount of heat that can be withdrawn from a reaction zone in a fluidized bed 0e within the reactor. It is customary for the heat to be removed from the reintroduced gaseous stream by cooling the stream outside the reactor. A requirement of the fluidized bed process is that the velocity of the reintroduced gaseous stream is sufficient to keep the fluidized bed in Alla fluidized. In a conventional fluid bed reactor; The volume of circulating fluid to remove the heat of polymerization is greater than the volume of fluid © needed to support the fluidized bed and to sufficiently mix the solids in the fluidized bed. However, in order to avoid excessive charge (transfer) of solids in a gaseous stream drawn from the layer “da” eal, the velocity of the gaseous LAD should be regulated. Polymerization is directly proportional to the rate of polymer production; The heat generated is equal to the heat absorbed by the gaseous stream and lost by other means so that the temperature of the layer remains constant. Gl has been around for some time; The temperature of the gaseous stream from outside the reactor; known as the temperature of the reconstituted current; This degree cannot be lowered without the dew point of the re-current stream. The dew point of the recycled stream is the temperature at which liquid condensation begins in the recycled gaseous stream. © It was believed that introducing a liquid into a re-phased gaseous stream in a polymerization process in the Aa" jes bed would inevitably block the re-stream lines and the heat exchanger and the area below the fluidized bed or gaseous distributor plate. As a result of operation at Z Jel temperature of the dew point of the reintroduced stream In order to avoid the problems associated with the TE present in the reintroduced gaseous stream, it was not possible to significantly increase production rates in commercial reactors without expanding the diameter of the reactor.

¢ There has been a concern in the past that excessive amounts of liquid in the reconstituted stream (sec or) might disrupt the liquefaction process to such an extent that the Longe da peal collapses to precipitate solid polymer particles into a solid mass causing Close the reactor. This very handicap belief in avoiding the presence of a liquid in a reconstituted stream can be realized from 0 | US Patents Instrument: 477,77; €€£,104.0M) (YAY) €0, and the European patent applicant Geno EV No 00. Contrary to this belief it turns out; eJenkins 11 and his co-workers have also discovered in US Patent No. 4,947 449 and related US Patent No. 5,5/8,74968 that > a reintroduced stream can be cooled back to a temperature below the dew point in the process of polymerizing the da" sae layer 8 resulting in a part of the returned stream being condensed again. The discovery of these two TI Jenkins patents has been included in the references. Then the resulting stream, containing the drawn liquid, is returned to the reactor without the occurrence of the aforementioned agglomeration and/or blocking phenomena as I believe It occurs when a liquid is introduced into a fluidized bed polymerization process This process is known for the purpose of introducing a liquid into a reintroduced stream; it is known in industry as a condensate in a gas-phase polymerization process. cTenkins 17 and co-workers; that, given a TAS Laie temperature of the recondensed stream to below its dew point in the "condensed form" process, it is possible to increase the polymer yield; compared to production in the non-condensed (form) mode; due to the increasing Cooling capacity TIT ¢ Jenkins and daa staff also found that a significant increase in the temporal capacity rate could be achieved; in the amount of polymer production in a given reactor volume; This is done by a “condensed toad” process with little or no change in the properties of the product. The liquid phase in the gas/liquid phase reconstituted stream mixture in the “condensed mode” remains carried or Glee in the gas phase of the mixture. Cooling of the stream returned again to produce this mixture of the two phases leads to a liquid/vapor equilibrium state. Liquid evaporation occurs only z vo when heat or ga fel ty pressure is added. The increase in spatio-temporal production rates achieved by cJenkins was 17 And the workers with it as a result of the increased cooling capacity of the returned stream from 140 nm

new; which in turn is due to both the larger temperature difference between entering the reintroduced stream and the temperature of the layer (Tang Aa" geal > condensed fluid carried in the reintroduced stream. 0 TT Jenkins and co-workers illustrate the difficulty and complexity of the control; general; and the attempt of 0 to extend the fixed operating area to make the spatial-temporal production rate in the gas-phase reactor the best Sa, and at 8 “rehabilitation” 11 and those working with it, the returned gas is cooled again and added to the reactor at a temperature below the dew point so that the fluids evaporate di AS inside the reactor. The capacity of cooling the recycled gas can be increased further while it is at a certain temperature of the cooling heat transfer medium 8. One test reported that isopentane is added to increase the dew point. This is because the cooling More can displace a larger amount of heat, and from it it is said that a higher time span is possible.Jenkins 11 and the ax workers recommend that the percentage of condensed liquid in the reconstituted gas not exceed 9671 by weight; preferably from ? to PAY By weight Some of the potential hazards disclosed include the formation of 'slurry'; maintaining a sufficiently high reconstituted gas velocity or avoiding liquid build-up on the dispenser plate. TT Jenkins and his co-workers kept silent about where the upper limits of non-polymerizable and condensable materials lie. And how to reach an optimal crop in the time space using the intensive pattern. This can be tuned with a gas bed reactor “da” see to give the desired melt value and Y density of the polymer at optimum production. Great care is usually taken to avoid conditions that can lead to the formation of lumps or sheets; dof worst case the da" sae layer is unstable it collapses or fuses the polymer particles together.therefore fluidized bed control should be exercised to reduce agglomeration and surfacing and to prevent bed collapse or to prevent the need to terminate the reaction and stop the reactor.this is the reason why Ole lial cia” ota in the commercial scale ve to operate fam within proven stable operating areas; the reason for which the reactors were used in a carefully defined way.

Even within the constraints of traditional and safe operation; The control is complex as well as the difficulty and uncertainty of experimentation if new and improved operating conditions are to be created. There are target values; Determined by polymer and catalyst “catalyst” for operating temperature; The ratio of synergistic ad gall(s) comonomer(s) to monomer is 0 and the hydrogen to monomer ratio. The reactor and cooling system were contained within pressure vessels. Cll its contents without conflicting with liquefaction by measuring other things: (1) pressure at the top (Y) pressure variation at different heights along the layer (3) temperature lal ascending towards the layer (£) temperature in layer Ae Ted) and the temperature of the stream ~ descending towards the layer Lad (0) Gas Composition 5 (1) Gas flow rate. These measurements are used to adjust the addition of the lial (¢) and to adjust the partial pressure of the monomer partial jai gall and the velocity of Recycled gas among others. restricted polymer removal; in some cases; These should also be monitored in addition to the ash level in the polymer on the design of the unit. The unit is a closed system. Changes during operation; in operation to one or more measured values lead to changes. results from them elsewhere.In unit design, capacitance optimization is achieved depending on the most specific component of the overall design.There is no generally accepted view of what causes agglomeration or surfacing.Clearly complex coalescence of polymer particles is involved;possibly due to insufficient heat transfer generated by insufficient liquefaction in the layer (Aa ped) however, up to this point no clear “©” relationships were found between specific modes, measurements, agglomeration and surfacing. Therefore all measured values and controls have traditionally been used to stay within known safe operating regions for the design Specific unit Large scale gas phase units are expensive and have high productivity The risks associated with experimentation in such units are great because downtime is costly It is therefore difficult to explore the limitations of designing and operating a Ga pad given the costs and risks It would be desirable to provide a method for determining the condition Stable operation of a gaseous fluidized bed polymerization Facilitate the best design of the unit and to determine the desired process conditions in the unit design

7 specific. The gt se will also provide lee for gaseous fluidized bed polymerization giving maximum reactor throughput. Therefore, among the objectives of the invention is to assist in defining stable operating areas for the gaseous layer process da Tea and designing a unit; To establish standards for a safe operation with a low risk of 0 defect; At the same time, high yields for the reactor; and/or avoid any reduction in total unit capacity due to reactor throughput. General description of the invention: The invention relates to a process for polymerizing alpha-olefins in a gas phase reactor with production rates much higher than previously imagined. The invention < - is directed toward a process for polymerization of alpha-olefins in a gas-phase reactor having an Aa" pee layer and an and medium where the liquid level in the fluidizing medium is greater than 96780 by weight on the basis of the total weight of the fluidizing medium. The invention is also directed toward Lad > A process for the polymerization of alpha-olefins in a gas-phase reactor comprising an Aa" ee bed and a fluidizing medium such that the change in enthalpy of the fluidizing medium exiting and entering the reactor is greater than 40 Btu/lb (4 + AF, joules/g). The invention furthermore provides a process for the polymerization of alpha-olefins in a gas-phase reactor at a production rate greater than about 5080 lb/hr-ft" (7 441 kg/hr m'). In another embodiment the invention relates to a method for determining stable operating conditions For a “©”-gas-phase fluidized bed polymerization reactor by setting a property useful for determining the stability of the Aa” sea layer and adjusting the composition of the fluidizing medium or reconstituted stream to determine a range of property values to maintain a stable operating condition. The invention is directed in the embodiment of another model as well towards a process for controlling a gas-phase polymerization reactor with an Aa Tee layer by checking the condition of the reactor indicative of deficiencies © terminal solutions and adjusting the composition of a dilute medium or a reconstituted current in response to solutions in order to avoid the occurrence of deficiencies. In a preferred embodiment, a stable volumetric density ratio is observed for layer 1 | 0

M

(FBD) da" pod to constant volumetric density (SBD) This ratio is maintained above

Approximately 204 this and the invention also provides in another embodiment a method for determining stable operating conditions for a gas fluidized bed polymerization reactor operating in a condensed mode that includes observing the 0 volumetric density changes of the fluidized bed in the reactor associated with changes in the composition of the fluidizing medium; As the cooling capacity of the returned stream increases again without exceeding the level at which the decrease in the volumetric density of the fluidized bed is irreversible. in general; A decrease in the ratio of FBD to SBD to less than 1.54 may include a risk of disruption (cracking) of the layer da pel and this

> What to avoid. .

1 In another embodiment according to the invention there is a gaseous fluidized bed polymerization process available for the polymerization of a polymer by passing a monomer comprising gaseous stream through a fluidized bed reactor in the presence of a catalyst under effective conditions to produce a polymeric product and a stream comprising unreacted monomer gases; They include the compression and cooling of the said stream; It includes the product of mixing the aforementioned stream with feedstock components and returning a gaseous phase and a liquid phase to the aforementioned reactor; And the improvement that includes cooling the aforementioned current so that

oe The liquid phase is more than 9615 and preferably more than 9670 by weight of the total weight of the reconstituted stream and the composition of the stream is such that Bila Ty on the ratio of the volumetric density of the fluidized bed to the bulk density of the stable is higher than about 1.54 at least. Brief explanation of fees:

will become targets; The features and benefits of the above present invention are clearer and more understandable when x reads the following detailed description Ge with the accompanying drawings; where: Fig. [1] : Lay is a schematic representation of the preferred model of the reactor used in the practical application of an enhanced fluidized bed polymerization process to produce the Gy polymers of the present invention; Figure [VY] : Lewy graph represents the molar percentage of isopentane and the volumetric covalent Yo of the fluidized bed from Table (1); m1

0 isopentanemole Graphically the molar ratio of isopentane Canny represents: [VY] the shape and volumetric density of the cantilevered layer from the table (?); and z. [©]. Figure [¥] compares Figure Lily Lay Figure [4]. : Represents: the detailed description of the invention of Bennett; In the following description; Similar parts through the specification and through the drawing with the same reference numbers, respectively. The drawing does not have to be to scale; The improved process according to this invention has been better illustrated in certain parts. The present invention is not limited to any particular type or class of polymerization reaction or Lay polymerization monomer specifically for Tam polymerization reactions. synergistic but conditioned and propylene ethylene one or more; For example, olefin monomers of ethylene monomer 0 4-methyl pentene-1 10-ntnb and 4-methyl pentene-1 1-ntnbo butene-1 1-topo propylene .. Western stern p80707©0. These monomers may include octene-1 1-ntcao hexene-1 1-nsco polar; And binaries that are on the intake or on the rotation and the monomers of acetylene and aldehyde. Cyclic metallocene and include a transition metal component or a metallocene 5-metal component or an alkoxy either with an alkyl or alkoxy component Jase penta-dianiyl one or partly and completely double Ada” ie Alf as a constituent of an ionic compound. These catalysts include material compositions including those catalysts modified by prepolymerization or by encapsulation such as capsules. Although; As mentioned above, this disclaimer of the present invention is not limited to any particular type Ye of phase polymerization gag nT vad) of the polymerization reaction; The following discussion is about operating the process, where it was found that the invention (Gla) is an example of that; Gaseous polyolefin monomers of the present olefin type are particularly useful. There is a possible increase; significant In the productivity of the reactor without an adverse effect on the quality of the product or its properties. Raising the list oe of the reactor may be lef and to achieve higher cooling capacities; Thus, the productivity of the dew point of the stream returned again to allow a greater increase in the heat removed from the layer

1 In order to achieve the objectives of this request, the terms Aad eal and the medium of exchange are used. The dew point of the reconstituted stream can be increased again by increasing the operating pressure of the DLE, diluting the reaction/returning system again, and/or by increasing the percentage of condensable fluids and decreasing the percentage.

Jenkins denaturation of non-condensable gases in the reconstituted stream in the manner that was shown by and 47,799 4,0. A0AAVAL and co-workers US Patent No. 0 condensate may be inert to the catalyst and to the reactants and polymer yield are synergistic and the condensate may enter the resulting comonomers; It may also include monomers. In the react/replay system any point in the system; Just as it will be shown later in the figure, Jody coals and for the purposes of this patent application, the term condensable fluids [1] is saturated or unsaturated. Examples of suitable saturated hydrocarbon ye fluids for condensation are easily volatile liquid hydrocarbons; And those that can be chosen are from saturated carbon hydrocarbons containing from two to / atoms of carbon from the appropriate hydrocarbons: propane; N-Butane day Sal saturated hydrocarbons Some hydrocarbons

Cs isobutane; n-pentane; isopentane; neopentane » n-hexane; isohexane and other saturated hydrocarbons; n-heptane; N-actane and other saturated ©, ©, and hydrogen carbons or mixtures thereof. Saturated. The condensables are synergistic monomers, including some Lay monomers for polymerization such as olefins; Diolefins or mixtures thereof or wholly incorporated into the polymer yield. Tiga mentioned above which may be required when applying the invention; Maintain the amount of gas in the reintroduction stream Ye and the velocity of the reintroduction stream at levels sufficient to maintain the liquid phase of the mixture such that it does not de peal the gaseous phase until the reintroduction stream enters the layer BE as the liquid accumulates In the lower front of the reactor under the spreader plate. The speed should be sufficient to support and mix the fluidized bed inside the reactor. The regenerated stream is also high and evaporates quickly. de It is also desirable that the fluid entering the fluidized bed be ve

Y40

1 It is important to control the composition, temperature, pressure, and apparent velocity of the gas with respect to 0 for the application. Aa" ee stratum identifies stable os al quantities under effective conditions without Alla and well mixed in A" Jae reactor particles or disrupt the operation of the current process JZ dant large aggregates (lumps or sheets) which 0 slope. | in one of the preferred embodiments over 9019 weighers and preferably ca ASH may be weighed from the reconstituted stream or it can be in a liquid phase without expecting BY more than liquefaction Provided that the safe operating limits of the Adee defect stable operation zones determined with the help of volumetric density measurements of the fluidized bed are not exceeded. : of current 9600) and during the polymerization process a small part (usually less than about

Oil) The gaseous gas flowing upwards through the fluidized bed. The main part of the reeboard that does not interact; It crosses to an area above the inclined layer called the clearance area, which may be a deceleration area. in the clearance area; The large solid Ley-bearing zone polymer particles that protrude (stink) above the layer in the frenzy of gas bubbles across the surface or in the gas stream; It is allowed to reflux into the fluidized bed. As for the small solid polymer particles; Known in the industry as “minutes,” they are swept away with the re-current; This is because their final deposition velocities are less than the velocity of the re-current in the clearance area. The operating temperature of the process is set to a temperature below this Jia ls, or the temperature of fusion or adhesion of the resulting polymer particles. It is important to maintain this temperature to prevent clogging of the reactor with polymer blocks; Which grows rapidly if the temperature reaches high levels. These polymer clumps can become so large that they are withdrawn from the reactor as a polymer product and cause process and reactor failures. like that; Ramp-current treatment blocks can disrupt the polymeric yield; So, for example; Adee organized an all-transportation intervention; drying units or tools ve

preferably in one of the preferred embodiments of the present invention; That the point of entry of the reintroduced stream be below the layer (da geal) in order to provide a regular flow of the reintroduced stream and to maintain the fluidized bed in a suspended state and to ensure the homogeneity of the reintroduced stream with water upwards through the fluidized bed. and in the AT form of the present invention; The current 0 is restored again; It can be split into two streams or into more separate streams; One or more of these may enter the layer Aa Teall provided that the gas velocity under and through the layer dal edd is sufficient to keep the layer in suspension; For example, the recycled stream can be divided into a liquid stream and a gaseous stream; which can then be introduced separately into the reactor. In applying the improved process of this invention; The reconstituted stream from a new © consisting of a mixture of gas phase and liquid phase inside the reactor under the distributor plate can be formed by injecting the liquid and reconstituted gas separately under conditions that will produce a stream that includes both phases. The benefits of this invention are not limited to the production of polyolefins. So, this invention can be applied to any exothermic reaction that takes place in a gaseous layer, Aa see, and more; Generally the benefits of operating a process in BS mode over other processes — directly as the dew point temperature of the restart stream approaches the reaction temperature within the underlying fluidized bed. The Gada process benefits for a given dew point may increase with the percentage of liquid in the stream returned back to the reactor. The invention allows high percentages of liquid to be used in the process. Yes a gas bed reactor “da” jaa has been shown to be particularly well suited for the production of polymers by the process Tp of the present invention; best illustrated in the accompanying drawing; It has been referred to; clases | by number (01) in Figure JV] It is worth noting that the interaction system depicted in Figure [1] is only intended for representation. The present invention is suitable Tun for any interaction systems da" yes The traditional class vo Referring now to Figure [1]; the reactor (01) includes a reaction zone (VY) and a clearance zone; in this case it is a reduction zone of velocity (£) (V1) as well. The ratio of vr

The height to diameter of the Taldiel reaction zone (VY) depends on the desired yield capacity and lifetime. The reaction zone (VY) includes a fluidized bed containing growing polymer particles; and on preformed polymer particles and small amounts of catalyst. The layer “dda” ad supports the reaction zone (VY) with a recycled stream or a diluting medium (0) generally composed of 01 feedstock stream and a second recycled fluid. The reintroduced stream enters the reactor through a distributor plate ( VA) in the lower andl of the reactor; which helps in uniform fluidization and support of the fluidized bed in the reaction zone (VY) and to keep the fluidized bed in the reaction zone (VY) in Ala suspended and viable; gas velocity exceeds Apparent Gas Flow (SGV) through the reactor” generally; the minimum flow required for liquefaction; which typically ranges from about 7 ft/s (fpr, TY) to 1.0 ft/s (107 sfp) and is best kept The SGV is not less than about 1.7 ft/s (0.417 m/s); and better yet, not less than 10 ft/s (20 m/s). SGV

best 0.0 ft/s (1.0 m/s); In particular *,? ft/s (0.107 Sfp) This helps the polymer particles in the reaction zone (VY) in the aia to be localized “hot spots”; it prevents entrapment and distributes the catalyst particles throughout the fluidized bed. Reactor (01) during operation, and at start-up, with an essential part of polymer particles before introducing the re-current flow (V1) These polymer particles should preferably be the same as the new polymer particles to be produced, except in cad if they are different The reaction is drawn together with the newly formed first product after the reinitiation of the reintroduced flow and the catalyst flow and after solidification of the reaction. of the present invention are often oxygen-sensitive, so it is preferable to store the catalyst in a catalytic reservoir (01) under a gas hood that is inert to the stored catalyst, such as, but not limited to, argon or nitrogen

This achieves liquefaction of the da ped layer in the reaction region (VY) at the high rate v s at which the reintroduced current (V1) flows into and through the reactor (Ve) and is usually the rate of inrush current flow Again (V1) is approximately 10 to 90 times larger during operation than the

1 VE The rate at which the feed enters the reintroduced stream (171) This recycled stream rate Mall (V1) provides the apparent gas velocity required to suspend and mix the fluidized bed in the reaction zone (VY) in the case of Aa ae The edie generally has the appearance of a boiling liquid with a dense mass of

Arad) particles in an independent movement caused filtration (leakage) and gas bubbing through layer 0 (VY) in the interaction zone da" peal through layer (V1) and during the passage of the re-current 0 again the pressure decreases. The pressure decreases This is equal to or slightly greater than the weight of the fluidized bed in the reaction zone Lapua (1 Y) over the cross-sectional area of the reaction zone (71); which sums up the pressure drop expected on the reactor geometry. ]; The feed installation enters the re-stream line (11) at, for example, but not limited to - point (17). A gas analyzer (14) receives gas samples from the re-stream line (11); and monitors the re-stream composition (V1) passing through it, and the gas analyzer (YE) conditioned Lad to regulate the installation of the re-stream line (V1) and the feed to maintain a stable condition in the re-stream installation (11) In the reaction region oe (VY) the gas analyzer sale (YE) analyzes samples taken from the re-current line (V1) at a point between the clearance zone (V€) and heat exchanger (776) Preferably between the compressor (YA) and the heat exchanger (773).The recycled current (V1) passes in a direction through the reaction zone (VY) absorbing the heat generated by this polymerization process. As for the part of the recycled current (V1) that does not react in the © interaction region (VY), it exits the interaction region (VY) and passes through the deceleration region or the clearance region (16). As mentioned above, in this region, the velocity reduction region (1), a major part of the transported polymer lags behind in the fluidized bed interaction region SU "Jia (VY), thereby transferring the solid polymer particles to the recurrent stream line from Once the recycled stream (176) is drawn from the reactor over the © clearance (VE) it is then compressed in the compressor (YA) and passed through the heat exchanger (13), where the heat generated by the polymerization reaction is removed. And by compressing the gas from the recycled stream vo, and the exchanger (Ve) is again in the reactor (V1) before the return of the recycled stream (V1) again (11) in dad) traditionally in type and can be By placing it within the thermal current line (YT) of this invention, it may be possible to have more than one Gy region in a vertical or horizontal position.In an alternative embodiment one heat exchange or from one pressure area may be included including the re-current line. .(01) at (V1) and by referring again to Figure [1]; The current returned again: (Fe), preferably; To fix a deflector (01) to the bottom of the reactor (V1) as it exits the heat exchanger, it prevents the polymer from (1) a fluid flow under the gas distributor plate (18). The deflector of the fluid flow precipitates in the form of solid mass and maintains transport of liquid and polymer particles within return stream and preferred type of deflector plate for fluid flow (VA) under distributor plate (V1). US Patent No. Centrally upward and check GY The use of a ring-type disk provides 4. Outward direction The central flow towards the top helps in transporting liquid droplets in the Glas head of the bottom and the circumferential flow outward helps in reducing Accumulation of polymer particles in (V1) to avoid diffusion of the recycled current (VA) head of the bottom.The distributor plate 6 operates centrally inclined towards a moving or sparkling current that may disrupt the dilution of (VY) entering the current zone Interaction (VY) in the interaction region da” all layer

The temperature of the ply fluidized bed is set at the adhesion point of the particles but depends mainly on three factors: (1) catalyst efficiency and catalyst injection rate which controls the rate of polymerization and conjugate rate ad gd © - temperature; (Y) degree The temperature, pressure and composition of the re-entrant stream and compensating current entering the reactor and (Y) the volume of the re-entrant stream passing through the fluidized bed.The amount of liquid entering the fluidized bed with the re-entrant stream or by entering separately as mentioned above affects the Temperature; liquid OY evaporates in the reactor and lowers the temperature of the fluidized bed.

vo is usually the rate of catalyst addition usually in setting the polymer production rate control.

The temperature of the Aa peal layer in the reaction region (VY) remains in the preferred model; It is in a steady state by the continuous removal of the heat of reaction. The reaction zone (VY) is steady state when the amount of heat generated in the process balances with the amount of heat removed. This steady state requires that the total amount of polymerization is balanced by the amount of 0 polymer and other material removed. As a result, the temperature; Pressure and installation at any particular point in the process are constants with time. There is no significant temperature gradient within most of the VY fluidized bed except that there is a temperature gradient at the bottom of the Aa peal in the VY in the area above the distributor plate of the gas ( VA) Lay This gradient represents the difference between the temperature of the returned stream (V1) entering through the distributor plate (VA) at the bottom of the reactor (01) and the temperature of the dead layer (V1) in the reaction zone VY) The Jd operation of the reactor (01) requires a good distribution of the recycled current (V7) and if the polymer is allowed to grow or formed and the catalyst particles to be deposited in the layer (Aa" pel) then polymer fusion can take place In an extreme case this can result in the formation of a solid oe throughout the reactor A commercial reactor of a given size will contain thousands of pounds or kilograms of polymer solids at any given time Removing a polymer solid of this size can be difficult Large;requirement for high Tags and long downtime.By determining stable operating conditions with the help of FBD measurements improved polymerization processes can be performed as it maintains liquefaction and dat geal layer support in the reaction zone (VY) within the reactor(01). ' and in the preferred form; Variations in the Aa peal volumetric density (FBD) of a given class of polymer and/or catalyst formulation are used to optimize process conditions for the unit design. The volumetric density of the fluidized bed is the ratio of the measured upward pressure drop across the GIS pe stabilizer portion of the reactor to the height of this stabilizer portion. It is an average value that may be greater or less than the in situ volumetric density at any point in the installed vo reactor portion. It is to be understood that under certain circumstances known to those skilled in the art; The measured mean value may be greater or smaller than the stratum in situ volumetric density.

wv The applicants have found that the greater the concentration of a condensable component in the gaseous stream to determine; There is a risk that the operation will fail if the ALE flows through the layer; It is possible to reach the point of increased concentration more and more. This point was marked by an irreversible decrease in the volumetric density 0 in the gas. The ca Kil content of the fluidized bed with an increase in the concentration of the acceptable fluid (the stream liquid returned back into the reactor) may not be directly related. and it happens»; Generally; Decrease 0 without a corresponding change in the constant bulk density (aed) in the layer volumetric density of the final product granules. and so on; It does not seem to include a change in liquefaction behaviour; Any permanent change in the properties (Aa ped) was shown by the decrease in the volumetric density of the characteristic layer of the polymer particles. The gas condensable fluid concentrations at which a decrease in 1 occurs depends on the type of polymer produced and on other process conditions aT ped) the volumetric density of the layer when the concentrations of the absorbable fluid increase dx “seal” by monitoring the volumetric density of the layer Sa A can condense in the gas for a certain type of polymer and for other conditions of the process. Other variables besides concentration Aa ped) Volumetric density of the apparent bed depends on the gas flowing through the reactor; de pull Sia led condensable fluid in the gas inc., fluidized bed height, constant yield volumetric density as well as gas and particle density temperature and pressure. Thus, tests were required to determine changes in the volumetric density of the fluidized bed that could be attributed to changes in the concentration of the detectable fluid that avoided changes of significance under other conditions. Therefore, it would not be necessary, outside the scope of the present invention, to monitor these other variables from which the volumetric density of the fluidized bed could be determined or which could affect the fluctuations of the bed imbalances. For volumetric purposes of the irradiated layer monitoring or ALA monitoring or maintaining this call includes maintaining those aforementioned variables described above that affect the volumetric density

Ar" peal) of the fluidized bed or used to determine the volumetric density of the layer While some moderate drop in the volumetric density of the Yo layer can be accommodated without losing control, other changes may be associated in the gas composition or in variables da ed)

A

Others that increase Lad — dew point temperature with an irreversible decrease in the bulk density of the layer Aa" eal and "hot spots" in the reactor bed; merging aggregates and possibly terminal shutdown of the reactor. Include other process outcomes directly related to the decrease in bulk density A fluidized bed has a reduced polymer capacity for a fixed-volume reactor drain system and a reduced residence time in a 0 polymer/catalyst reactor at a constant polymer production rate.The latter may, for a given catalyst, reduce catalyst yield and increase the level of catalyst mites in the resulting polymer.In a preferred embodiment it is desired to Minimizing the concentration of the condensable fluid in the gas relative to the production rate (Toma) of a target reactor and associated cooling requirements. padi ty the composition to achieve much higher cooling capacities relative to the recycled stream (without encountering layer fluctuations) by cooling that composition to a greater degree ALE condensing materials other than ALG may be added for polymerization and in proportions appropriate to a particular class to yield High for the reactor while maintaining good conditions - in layer Aa Tedd by remaining within the stable operating layer thus defined. It can achieve high throughput reactor in a process or; In terms of unit design; It can include a large capacity unit with a relatively small Jolie diameter, or it can modify existing reactors to provide increased capacity without changing the size of the reactor. It was found that at high reactor yields; By staying within the limits specified by the acceptable fluidized bed volumetric scout changes; Condensate fluid levels higher than YY 96700 BVO 9675 or even 9670 can be well adjusted avoiding levels of; significant For agglomeration or surfacing resulting from the disruption of the layer Ae peal and the levels of the condensate liquid range on the basis of the total weight of the stream returned again or of the fluidizing medium between 10 BY weight and preferably greater than 0 to +969 weight and the best is from 9680-77 The best weights of Zafadl are from ‎“~Y0 965 ve and Zetha.

Preferably 5 ASH aay volumetrics of the fluidized bed using a measurement in differential pressure of a portion of the fluidized bed that is not subject to misalignments above the distributor plate. And while the volume density changes of the normal (da Ted) layer in the lowest part of the layer (A Yo) can be counted on the layer disturbance above the distributor plate; so that the volumetric density 0 of the upper Aa "peal" measured away from the distributor plate is used as a constant reference; it is now found surprisingly that changes in the volumetric density of the upper fluidized layer correlate with the change in stream composition and can be used to find and define operating zones Beneficially the reconstituted stream is cooled again and quickly passed through the reactor such that the cooling capacity is sufficient for the reactor throughput; expressed in pounds of polymer per ª hour/ft' of reactor cross-sectional area; exceeding 5000 lb/hr-ft" Ye) kg/h-m'); and in particular 001 lb/hr-ft' (7979 kg/hr-m') including a change in enthalpy of the recaptured stream from reactor inlet conditions to reactor outlet conditions of not less than fr btu/lb; Preferably 00 calories. british/lb. Preferably, the liquid and gaseous components of the stream should be added in a mixture without a ro plate distributor reactor. This reactor throughput is equal to the spatial production rate multiplied by the fluidized bed height. and in the preferred embodiment of the present invention; Tran fy the fluid entering the reactor (01) to achieve the benefits of the increased reactor cooling capacity for this polymerization process. High fluid cgi in the bed can promote aggregate formation, which cannot be broken by mechanical forces present in the © > layer; potentially leading to de-liquefaction; bed collapse; and reactor stoppage. In addition, the presence of fluids can affect spot bed temperatures and affect the process's ability to produce a polymer with compatible properties; Tokai because this requires a constant temperature mainly In the entire layer. For these reasons, it was required that the amount of liquid entering the dal ad layer, under a certain group of conditions, not exceed the amount that would evaporate in the lower region of the fluidized layer. Distributor plate; sufficient to break up sludge formed by the liquid-particle interaction.

And it has been discovered in this present invention that for a particular composition and for pal ad the physical yield particles in the fluidized bed; and for a given reactor of other or related type and recirculation conditions by specifying boundary conditions Aha of the composition of the gas flowing through the bed; can maintain the ALE da" ee layer for use at high cooling levels. While it does not wish to be bound by any theory; py the applicants state that the observed decrease in volumetric density of the fluidized bed may reflect an expansion of the dense particle phase and a change in Bubbles behavior within the fluidized bed Referring again to Figure [1], catalytic ages are added, if necessary, to the used catalyst, and in the direction of the current descending from the heat exchanger (11) and the catalyst reagent can be entered from the distributor (YY) Recycled Current (V1) However, the Gay A Sad process of the present invention is not specific to the catalytic activator insertion site or any other required Clip <a as catalyst boosters. gin from the catalyst reservoir either intermittently or continuously in the fluidized bed reaction zone (VY) at a preferred rate at the point (TE) above the plate-gas distributor (VA) and in the preferred form as mentioned above The catalyst is injected at the Cus point mixing with the polymer particles inside the fluidized bed (VY) is best.Since some fan Aad catalysts necessitated that the preferred injection be to the reactor (01) above the gas distributor plate (81 ); and not without it. so. Lay Injecting the catalyst into the region below the gas distributor plate (VA) resulted in the polymerization of a carrier in this region; This may have eventually blocked the © plate of the (VA) JW distributor as well; JAY catalyst on top of the gas distributor (VA) plate helps in uniform distribution of the catalyst throughout the entire fluidized bed (VY) and thus helps prevent the formation of "hot spots" caused by high local concentrations of catalyst. The preferred injection is at the bottom of the fluidized bed in the reaction zone (VY) to provide uniform distribution and to minimize catalyst transport into the reconstituted line where the polymerization has resulted in a final blocking of the reconstituted line and the heat exchanger.

Various catalyst injection techniques may be used in the improved process of the present invention, for example the technique mentioned in US Patent No. 7 is incorporated herein by reference. It is preferable to use an inert gas such as nitrogen or an inert liquid that easily volatilizes under reactor conditions to carry the catalyst to the 0 region of the fluidized bed reaction (VY). The polymer is in the (VY) Aged layer reaction region and the rate of yield of the polymer can be easily controlled by adjusting the catalyst injection rate. It is maintained in the preferred mode of operation of the reactor (01) using the action or pressure Ly of the present invention This maintains the height of the fluidized bed in the reaction zone (VY) by withdrawing a portion of the polymer yield at a rate compatible with the formation of the polymer yield. It is useful to use instruments to detect any change in temperature or pressure across the entire reactor (V+) and the reintroduced stream (11) to monitor changes in the Ala fluidized bed in the reaction zone (01). These machines have either manual or automatic (self) adjustment of the catalyst injection rate, temperature, or recapture current.The yield is still removed from the reactor during reactor operation (10); via a drain system (6).It is preferable that Ty is drained Polymer: Separation of fluids from the polymer yield.0 These fluids can be returned to the re-stream line (V1) gas at point (YA) and/or liquid condensate at Ansty (40( Ril) '. Polymer yield to ramp current treatment at point (£1) The polymer yield conjugation is not limited to method Ad) in Figure AV] method x. shows only certain conjugates. Other drainage systems may be used; For example; Those disclosed and protected in US Patents No. 4,547,344 and No. 4,587,796 of Jenkins and his staff. Gig of the present invention; Adee offers to increase reactor throughput in polymer production in a fluidized bed reactor using an exothermic polymerization reaction by cooling the re-stream from a new ve below its dew point and returning the resulting re-stream to the reactor. It can be returned 010 |

YY

weight of the liquid may be returned to reactor 9671 with the reconstituted stream included more than at the desired temperature. dal weal to maintain this layer and the processes of the invention can greatly increase the cooling capacity of the tube for the stream The reconstituted stream or for the fluidizing medium by evaporating the condensate liquids carried in the reconstituted stream and as a result of the large temperature difference between the reconstituted stream 0 entering and the temperature of the fluidized bed. and chooses in the preferred form; Synergistic polymers resulting from copolymers or homopolymers and homopolymers, preferably from 0.59 to 9.0 to 0.001 and ranging between MI of a membrane class having a melting index to 0.97; Or a SnoSpec material that has a melting index of 141 ranging from 0.9 and a density ranging between “0

Sear to AY and a density between 151 and preferably from ; to tos to 1.1 between

Veo Preferably who? to Vo to 0.00 Densities have a melting index ranging from Ale to 0.997; Provided that all density units are g/cm” and are 1.94 and a density ranging from, according to the ASTM method, Gy, the melting index unit, g/10 minutes; assigned E. status (ASTM-1238) to the target material; It can transform different conditions in providing Bly yo levels previously. J 788 75 Productivity of a membrane class reactor, for example, is for the recycled current from sale, where it can first produce Elsie 0, to 0 ,7; Preferably from 0600 ranging from new butane/ethylene with a molar ratio of 0.08 to 0.000 preferably ranging from 4-methyl-pentene-ethylene or a molar ratio of © to 0.7 preferably From 000 range from hexane ethylene molar ratio Sarr dA > preferably eo) to 05000 range from octane-1/ethylene 4d so molar ratio dE to 0 preferably o ,f ranges from zero to hydrogen/ethylene to 0.09; A molar ratio of 7 isohexane mol or a level of 0 ranges from ? to isopentane to 7,0; and a level of 10 BTU fo mol and the cooling capacity of the regenerated stream is 9600 to 0.9 ranges from at least 0.9 BTU/lb or is at least 00 BTU/lb; Preferably ©

Ls 96718 preferably greater than JY percentage by weight of the condensate 961 by weight over 6 y vr that the process be used to produce an ingot; the recycled stream has a Gall ratio and the geo to 1.1 preferably on, to 1.001 molarity ranging from butene-1/ethylene to 0.08 preferably from eno to 001 ranging from 4-methyl -pentene-1/ethylene molarity of L to 0.0; preferably from 00 to 0001 ranging from hexane/ethylene or molar ratio of 0 to 0.07 to 1.0 preferably 0.000 ranging from octane-1/ethylene or molar ratio 1.17 p 1.8 to 17 ranging from 0 to 6, preferably hydrogen/ethylene molar ratio 4 to 09 ranges from isohexane mol or level 96700 oh © to Ju isopentane and level BTU/lb at fo mol and the refrigeration capacity of the re-stream is Btu at At least or the percentage by weight of the material is Bang 00, preferably BY by weight. 96700 condensed at least 9615 by weight, preferably greater than © density by a process that the re-stream has a ratio of Alle as well; varieties of or a ratio of 1.16 to 0.0001 to 0.7; Preferably from 1000 molar butene/ethylene range from 0.011 and preferably from 176 to 0.0001 molar range from 4-methyl-pentene-1/ethylene to preferably from 1, 159 to 0.000 hexane/ethylene molar ratio dee NY to 00' preferably 1.001 octane-1/ethylene molar ratio SEV to 0 001 1.6 ranging from zero to ethylene (hydrogen to .07; molar ratio 00 safe to 96468 mol or level 01 ranging from isopentane to 1; level 1.7 preferred of Te mol and the refrigeration capacity of the recycled stream BY ranges from © to isohexane Btu/lb to at least VY BTU/lb; preferably greater than BTU/lb lbs or VO and better greater than OHI. by weight. at least 96700 by weight and preferably greater than 9611 by weight for condensate. Examples To provide a better understanding of the present invention including its typical benefits and limitations are presented. Examples of this invention. Complex (complex) of tetrahydrofuran, butane chloride (iss) magnesium, titanium chloride reduced to diethylaluminum chloride (the molar ratio of diethylammonium chloride to tetrahydrofuran is 4,0) and tri-n-hexylaluminium (mole ratio: Tri-n-hexyl aluminum to tetrahydrofuran is equal to 7,©) impregnated with 0 (TEAL) dioxide. The activator is triethylaluminum Wl silicium treated with tertethylaluminium. Figure (1) The data in the table shows the gradual increase in the level of isopentane to achieve the increase in cooling necessary to obtain higher reactor productivity. This example shows that excessive amounts of isopentane lead to changes in and ultimately to its imbalance with the formation of hot spots and agglomerations necessitating the shutdown of the reactor bed. The higher the concentration of isopentane, the lower the volumetric index of the fluidized bed; This indicates an increase in the layer height. Lad is reduced on a change in layer liquefaction; which causes the catalytic modifier to reduce the level of the layer. In addition, the isopentane concentration was reduced in an attempt to reverse the change in the fluidized bed. However; at this point; Although the height of the layer returned to the normal height; The imbalance with hot spots and clumps in Layer 1 was irreversible and shut down the reactor. 'do

Yo (1) Table Time (in hours).

YA for yo 7 Ye 77 1

YOY LANEY LAY LA HEAT LA hE hy 0 RESIN MELTING (degrees/10 minutes) dy LA “Let it go” LANEY LAY LA ANAT RESIN DENSITY (g/cm): Recycled current compositions (from my grandfather) no £0.4 £4, £¢,) 21 1 7/6 ethylene 19.0 YA ATLA WY, “no YAY 1 km butene-1 1-ntube hexene-1 10-Nskeh 4m AY 4 Ur 7 q,¢ q,0 hydrogen 7,7 11 8 Yo WY 01 Ae isopentan Saturated isopentane Cg Hydrogenated carbonate

Cs Saturated hydrocarbons

YY LY EY YA A C 61 1.2 nitrogen (nitrogen) ¢ \,¢ ra mra lama vir ethan ethane methane saturated methane Cp hydrocarbons Saturated hydrocarbons

Y10,0 YIAA “NFA Recycled Gas Dew Point Sec (2°) 4 Mada Merkala Lakal YLY Lafla VEY Regenerated Gas Dew Point Sec (*m) 1 Width

YELY Yoo, ¥ VES, reactor inlet temperature (<°) 11 7 nm

We Mey te IXY TVA oY

YASY YALA YAY) YAY, A YAYLY YAY,Y 0 The temperature of the reactor (°<) “Raga No. AEA AYA AYA ATV Kalah AY The temperature of the reactor (*m) Like the words of Tom Fie TIA Reactor Pressure (psi) Standard YATRA 11 Meter YAY YYEV,Y 11 d Reactor Pressure (Standard kPa) 010 0

Yi

LAY Yee NAY Hot I NY 7,794 eli Apparent gas in de (ft/s) lac bitumen ed lac Gy GY Apparent gas velocity in the reactor (m/s) 0.6 f0, A O)Y 0 Height of the reactor bed (feet) 4 00 0 m 4.00 A standard number of leftovers AWRY Height of the reactor bed (meters) 7 Unless the stable volumetric density of the resin

Yad Lamar Arga (TOY YOY YOY YL)) (lbs/ft Fixed volumetric density of the resin (kg/m) » 87 films of the acidity of Rim Akhla Al Wakala fluidized dial reactor Volumetric density

Yo, A as a solution AVY other than YAY NAT 4) (lb/ft Volumetric content of the reactor bed for what YIY,Y is customarily thinner Yd... 4.3 ¥.YA fluidized (kg) /m) Ratio of the volumetric density of the sintered layer to the volumetric density oy lac d 604 a le NY stable spatiotemporal production rate

VY LEG 18 FEET 4 AN (lb/hr-ft) SPATIAL RATE NO MITA Vee VERY bitter YoY, (kg/hr cm") 0¢, 4 0 8 8941 47 WV (pounds per hour) -- m (call) production rate

YEA YEE QARRK QRA FLY 1 Production rate (ton/hour).

FEY 37210 vi. £14 1 £1 reactor productivity (lbs/hr-ft") and reactor yield (kg/hr-m") 13 Hg given for a load so enthalpy change of reintroduced stream (Btu /lb) ve Yv £Y £ 2 £Y 0 did not change the enthalpy of the returned stream (kp/g) YA V4 711 YY YY YY YY

Yv: In a second experiment; Table (?) and figure [©] also show that with the gradual increase in isopentane concentration, the volumetric density of the layer “da” eal decreased as expected from Table 0 (1). However; increased; this time; The volumetric density of the dal dl layer gradually increased as a result of the reduction of the isopentane concentration, and so on in this case; The change was in the liquefaction class

° responses and reversals. Yao

Ya

Table (?) Time (in hours).

YA 1 1 1 q l ° ¥ 1 01/min (Resin index of melting 8 Yel 7.4 minutes) 7 4840 times YA

GUAT Kaflaki LAAT LAIYY GAYA GANA) LAVA Resin Density (g/cm") by Lalah Kaflaky

Oa) Aili Structures of the recursive current (serious) Z oY,A oY,A Adv. 81 oY, oY, oY,A,K 7 ethylene Yo 0 Ye 14,1 pg Y4 Y 0 Yo NAY YA bitter butene-1 , 7" dd Vay q,0 14 isopentan

AN L 1,0 1,0' No 1Y L Ae AY nitrogen A B A B A A vod Ye Ye 1 \,Y ethan ethane methane saturated carbon dioxide Hydrogen: Cg Saturated hydrocarbons Dew point of reconstituted gas again Rada celebrate. All three shafts, spear 4 except for 11 (<°)

WE TAA YA 7, 7L Yi TULA IA (00) Dew point of reconstituted gas Reactor inlet temperature Nka 17 0 71 YY,Y A gradation of Arthral Matta (<°)

: Ya o.,1 thousand oy o1,Y ov, A OVA date EVA 0 81.7 (6°) Reactor gas liquid reactor inlet temperature sec (% by weight) YY, YES YYX 1 7 YEY No reactor temperature (<°) 00 ALA YALA MAYA YAYLY YALA YALA MAYA YAYLY reactor temperature (2°) AYA Ag, ALY ALY Ago AS) ALA 020 reactor pressure (pounds/inch) RA RMAF RMAF RMMC CAN YOU KICK FIVE PITA Reactor pressure (standard kilopascal) YAVL,Y YIVEY YIVY,0 YAVE,F Let us know the apparent gas velocity in the reactor. .

LYE LYE Alar LYT OLY YT Zoo WE avy (ft/s) Apparent gas velocity in the reactor ... (m/s) ot of 4,08 OF oF of FF “m” reactor bed height ( ft.)

Y4,¢ Raha 77 4.1 Ya, YAA YAY Y¥4.9 Y4.4 ) (lb/ft) Continuous Volumetric Density (kg/m) of resin (kg/m) dated EVO,A we used to leave £106 Volumetric density of the reactor fluidized bed (lbs/ft") ETAT Rala FYVO ALA A a da ad to GIA te Lay volumetric density IY LIV LTT LTE stable at

Spatial production rate (lbs/hr-ft) Ny ay Lala ia Nal NY 4 9.1 4 TREN temporal production rate (kg/hr cm) 4 YYALY YoY within Laga except 1 fla61 Production rate (thousands of lbs/hour) Reactor (lb/hr - £1Y 177 16 0.4 £4A EAA 4 7 (px £10) Reactor Yield (kg/hr-m') 4 Vahka 1 1 Yate YYVe YEAS YEYY 91 Enthalpy Change of Returned Stream (UK CAs/lb) oY 51 oY co 1 1 1 oq ot Enthalpy change of reintroduced stream (kcal/g) YA 719 1 ve vy ve ry Yr. 719

10

So; Figure [4] shows; It is a representation of the results of both forms [1] and [7]”; Clearly a point at which changes in bed liquefaction are irreversible due to excessive use of a condensable fluid. This point is determined by Cua when the ratio of the volumetric density of the fluidized reactor bed to the static volumetric density of the reactor bed is less than 0.99. Example (1) clearly shows, compared to the discovery of Jenkins and his co-workers, that there are fas for useful condensables.

For optimal spatiotemporal or Jolie throughput in cit AC mode

Example (7)

The following examples were made; mainly; In the same way as in Example (1) using the same type of catalyst and activator to produce homopolymers and synergistic polymers.

copolymers | 0 of ethylene butane (5 syfethylene) with different densities and different melting furnace ranges.

YY

Table (?) Experiment ° ¢ v Y 1 1,4 YY XY V,A4 Ve AT Resin melting index (degrees/10 min) km 8 +4 “,q0YY Resin density ( g/cm) for Elkhalky Compositions of Recycled Current (from my grandfather) 0 ethylene 57.1 ethylene 8 m 2 (ay 01 yay V¢,4 Yoox butene-1 hexene-01) hexene-1 1” hydrogen 1 Yo, 1,0 VY AS hydrogen 11,4 isopentane isopentan No La Car VEN 1,1 Saturated Cp 01 Vie Cs Saturated hydrocarbons AY nitrogen V¢,4 q,¢ AA ethane q,¢ VV ethan £0 m vy methane oY 111 methan saturated hydrocarbons Cp .t Cs Saturated hydrocarbons, + dew point Reconstituted gas (°<) 6 YEA 0 011 YAR YY A Reconstituted gas dew point (6°) AY VA, TY, A for 6” Reactor inlet temperature (°<) 17 Others Yo, VY Reactor inlet temperature (*m) indl (ov,Y £V,1 £Y,) 87 The liquid in the reconstituted gas (96 by weight) 78 76.40 Ra The average temperature of the reactor (°<) “Ara 01 01 VA and reactor temperature (*m) 1 C 1 0 C “Cm ry 97 YyEY Y44,A 0 reactor pressure (psi” standard) No. YAVRLY reactor pressure (standard kilopascals) ) Apparent gas velocity in the reactor (ft/s) 14 1 aa 6 no 07 "lm AS .,0¥ Apparent gas in the reactor (m/s) de ju £01 a 7, 7 £V,Y reactor bed height (ft) 7.4 aed VF, VE of reactor bed height (m) a Y¢,0 v4, add YAY Constant volumetric density of resin (lbs/ft) YaY, e £16. YY). fort ("af oS) Static Resin Volumetric Density 11 yo,v YY ay 14.1 Fluidized Bed Volumetric Density (lbs/ft)

Yeo vy Ray Qarla Adra 0 164600 (kg') dal ed Volumetric density of the reactor bed Density JY Aa peal) Volumetric density ratio of the layer 16 "6 8 8 Stable Volume 14" to 8 vy VY, VEY Spatial production rate (lbs/hr-ft') Production rate (thousands of pounds per hour).

YY, ¢ Yo,v £44 £0.9 YA,” Production Rate (ton/hour) 117 vey 01 17 Reactor Productivity (lb/hr-ft) None Except Vive Yite YYAY Yivo 0 Reactor productivity (kg/h division") Enthalpy change of reconstituted stream (unit

Te £4 ve >11 Btu ve >11 btu ve y YY £Y vy y Y £Y vy m re These experiments demonstrate the benefits of higher reactor throughput at exposed liquid levels by weight while maintaining the ratio of the volumetric density of the fluidized bed to the density of 9671 exceeds: | At least 1,949 stable volumetrics, and due to processing operations with the direction of the current, for example; yield drainage systems; extruders and the like; required to address specific reactor conditions; In order not to exceed the capacity of the unit 0 road (in the examples shown oe) Lila total. Accordingly; It is not possible to present all the benefits of this invention in the table (©). Z The apparent gas velocity (oF) from Table (1) was kept for example; in the experiment, it was low at about 1.14 ft/s, and therefore the apparent spatio-temporal production rate was lower. At a speed of about 7.4 ft/s, Ala can be much more than what was in 15.7 lb/hr.

Asie and Alle ratio and (¥) from Table (©) the effect of operating a reactor at an apparent gas velocity (7) and the spatial-temporal production rates of .96718 for the condensate were much higher than Ag lb/h-ft' Which indicates a significant increase in the rate of 1.1 and VEY achieved about high production (STY). 1); a Jenkins experiment such as this is shown by ft/s at a liquid weight percentile of 1.4 from Table (7) an apparent gas velocity of (£)

STY condensed 967.8 lbs. If the speed in the experiment (4;) is increased to ¥ ft/s, it increases to lb/hr-ft. And if the speed in the experiment (0) is increased to 18 to 18 VY resulting from lb/hr-ft. For all 117 ft/s, the spatio-temporal production rates increase from 9.8 to at least © with respect to Density 1.54 from Jef to (0) keeping the ratio of (1) experiments to the stable volumetric density. (Aa sad) volumetric layer. (7) Example The data for the cases were calculated In the theoretical example (©) and table (£) extrapolated information from actual processes using known thermodynamic equations vo

Yo | Tas in technique to highlight target adverbs. These data in Table (2) illustrate the benefits of this invention if you exclude the limitations of auxiliary reactor equipment.

Table (£) Series of experiments (1) Series of experiments (Y) Condition Y 1 g ¢ Y 1 f 31 resin melting index (deg/10: min) “AT kar resin density (g / cm") 11/7 1777 Compositions of the current returned again (from my grandfather) 8 0 aa aa 07,1 57,1 or oY, ethylene ethylene Yo ¥ Yor YY Yo, butene-1 1-ntop 21 1 1 1 hexene-1 Saturated Cg Hydrocarbons 01 & 01 Except for Cs Saturated hydrocarbons A No 7 7 8,9 AY AY AY nitrogen Ao A,0 4, 4, “A VY” Ara \, V ethan + I Yel Vel methan

YAAY Arachal IVY,T 0 1 Dew point of recycled gas again (1 h) Fa Kamal Rakta

ALA ATA YA, VA, Yoo WA WA IY,A Returned gas dew point (*m)

AOS, You, Yau, 101 01g Reactor inlet temperature (°<) 7 qR Rma 7 ra YV,A £Y,) £41 £4.7 £1,Y £1, (¢°) reactor inlet temperature

FAR YY, Yo, ¢ £¢,Y YEE YAT YAT The liquid in the gas returned again (96 wt.) 6 /46 4A, 4A, Ag, AEN AEN AEN (2°) Reactor temperature

Reactor pressure (psi) vax Tio Yio ¥Voy 6,7 (ul rn rr)

Ya14,Y 0 01 affected 71 Larkt TIVELY YAVLY YAY Yavay Reactor pressure (kPa) 0 | . Apparent gas velocity in de 1 1 AA Y,¢ (ft/s) 1.14 3s Apparent gas velocity in the reactor AAA (m/s) vy ey Alleles “AE” AE YF k Every 6 1 6 6 £v,Y EV,Y EV,Y gv,Y Reactor bed height (ft) reactor bed height (m) 4 < 64 a m 171 171 17 1171 spatiotemporal production rate

Y4,A AYA you VE, EY OWA ‎(lbs/hr-ft'): Hr Raqqa Temporal spatial production rate (kg/hr cm") VVY,A 6.40 sq ft "YYAA" for this FAV,U Production rate (thousands of lbs / hour) for YALE YEON "Rahn Rala Irma" mm0

WY ava ou) {0.4 ALY IRA 0 YA production rate (ton/hour) reactor throughput (lb/hr-ft") no 0 0 VAY 1” 114 7 L Ao) 0 Reactor productivity (kg/h-m"), according to Fedeker, Yolo, Tanaf | Add 7 191 YVY. lunch Enthalpy change of reintroduced stream (q. AY vi 14 sow 1 wo bht/lb) Enthalpy change of returned stream 84 go £Y YA YA oy EY vy rv again ( price/gm).

YA’

In series of experiments (1), there is an increase in the apparent velocity of the gas from 0.14 ft/s to 7.4 ft/s which leads to a higher STY of Vo, lb/hr-ft"; Compared to the initial value of 0.8 lb/hr-ft. And in another step; The reintroduced stream cools the interior of a EY to 4007 m. This cooling increases the condensate level again (sec) to

%YEE 6 by weight and allows an additional otal in 81577 to VAY and in the last step; The gas composition changes with increasing concentration of the inert condensable gas. isopentane; Thus, the cooling capacity is improved. And by this means; The sled Ga” Sa level again increases further to 9644.7 by weight and reaches 8777 “,77. Overall; The incremental steps provide an increase of 961,176 in production capacity from the reactor system. 1 and in the series of experiments (oY) the temperature of the reintroduced incoming stream is lowered from 7.1 mm to C. This cooling increases the ratio of a TAA again (sec) from 97675.4 wt to 96771 wt and leads to an increase in STY from VEY to 19.7 lb-hr-ft.” In another step; “3 3 concentration of hydrocarbons© from 967 mol to 9000 mol. This improvement in cooling capacity allows for an increase in STY of up to 17.8 lb/hr-ft. As a final step to demonstrate the value of this improvement, i TES TS returns the temperature of the stream Jalal to 79 seconds. This additional cooling allows the 8777 to reach 19.4 lb/hr-ft" when the condensate level of the recycled stream reaches 96778.6 wt. Overall, the incremental steps provide a capacity increase of 9679 by The reactor system, and while the present invention was described and clarified by reference to dala models from that, it will be appreciated by the right of those who are knowledgeable in the technology that the invention is subject to changes that are not necessarily explained here, such as, for example, that it is not outside the scope of this invention to use a catalyst of increased efficiency for increasing the rate of production or for decreasing the temperature of the recycled stream using refrigeration units.For this reason, it was necessary to refer only to the appended claims for the purposes of defining the real scope of the present invention.

Claims (1)

Ya 1-1 Process in Polymerizing Alpha-olefin(s)-olefin(s) in a Gaseous-Phase Reactor Including a Fluidized Bed and a Diluting Medium Where the Liquifying Medium Helps to Control the Aas 7 Cooling the Reactor The aforementioned 6 includes the improvement of using a level of liquid in the fluidizing medium inside the reactor, which is in the range from 17.4 to 9650 by weight based on the total weight of the fluidizing medium ° and maintaining a ratio higher than 54 regarding the volumetric density of the layer da pad 1 to volumetric density. Y—1 operation according to claim ( \ ) dua Liquid level within the range from YY to Y by weight based on the total weight of the fluidizing medium. 1 ¥— Operation ag of claim ( \ ) Where the liquid level within the range extending from Yo to Y0 is by weight based on the total weight of the fluidizing medium. Total fluidizing medium in the range from 0 to 0% by weight.—o0 1 Process under claim (1) where the polymer yield is withdrawn at a rate greater than about 0 Y lb/h-ft.” 1 1 The process, ad, of the claimant (1), where the aforementioned dilution medium includes: (a) buten-1 buten-1 and ethylene with a molar ratio ranging from about 0.001 to 7 about 1 ,7 or 4-methyl-penten-1 4-methyl-penten-1 and ethylene with a molar ratio ¢ ranging from about 0.060 to about 0.8 or hexen-1 And ethylene $e ° with a molar ratio of about 00 to about 1.7 or octen-1 and ethylene 1 with an Ad se of about 0.001 to about sto) For (b) an inert condensable fluid that includes from about 0.9 to about 96701 moles of medium ,. liquefaction A | in a molar ratio with respect to hydrogen of the process according to claim (1) in which hydrogen is present —V 1 ent ranging from about zero to about ethylene of ethylene 1 = A process ig of claim (1) where The inert ciAl fluid is isopentane .isopentan Y 1 4- Process ig of claimant (A) where the concentration of isopentan ranges in a medium ,. molar %Y to about Y deliquescent of about Y -0 -1 Gay process of claim (1) where the condensable Jalal is isohexane .isohexan Y -11 1 The process according to the claim (+1) where the concentration of isohexan ranges in - mol 9600 to about 0.9. The aforementioned dilution is about Y: where Said liquefaction medium (1) includes the process according to claim 11-1 Y (a) buten-1 Vis and ethylene with a molar ratio ranging from about 0.001 to Y about 1.6 or 4- Methyl-penten-1 4-methyl-penten-1 and ethylene with a molar ratio: ranging from about 1001 to about £0 or hexen-1 hexen-1 and ethylene °o with a molar ratio ranging from about 0.0001 to about 0.7 or octen-1 and ethylene 1 sn) to about 0.001 with a molar ratio ranging from about 1 mole ethylene from medium 70718 to about 0.9 L. With a molar ratio of hydrogen in which the hydrogen (VY) is present for the protector Gly the process 1-1" 1 A ranges from about zero to about ethylene with respect to ethylene Y is isopentane Catal where the inert convertible fluid (VY) of protectant Gg Process VE) isopentan Y in isopentan medium where the concentration of isopentane (VE) of protectant Gig Process 1 -1 hd se DY ranges to about 1 The aforementioned dilution of about 1 wherein the inert condensable fluid is isohexane (VY) of claimant Gay Process 7-1. isohexan Y in the medium of isohexan of claimant (5) where the concentration of isohexane ranges from ( a Process 17 - 1 molar. 961 Said dilution from about N to about Y The process according to claim (1) where said dilution medium includes: —1 VA with a molar ratio ranging from about 0.001 to ethylene 1-buten-1-ntop_(a) Y with a molar ratio of ethylene and 4-methyl-penten-1-1-ntnb-lethem- or 1,7 towards 1 ethylene and ethylene hexen-1 1-neskeh or +,Y0 to about 0.601 ranging from about ¢ octen-1 1- recline or v0 with a molar ratio ranging from about 0001 to about ° steel to about 10600 with a molar ratio of about ethylene and ethylene 1 (b) an inert condensable fluid comprising from about © to about 6 moles of medium A dilute -0 -1 process according to claim 1 A ( in which hydrogen is present in a molar ratio of 1 with respect to ethylene ethylene ranges from about zero to about 0.0 -0 1 Process Gy of the protectant (VA) where the inert condensate is isopentane A.isopentan -71 1 is the process Gig of the protectant (Yo) where the concentration of isopentan in the aforementioned anal Y ranges from about 1 to about 906700 moles. —YY 1 Process according to claim (VA) where ESN is isohexane .isohexan Y: –YY 1 The process according to the claim (YY) where the concentration of isohexan in the aforementioned dilution ranges from about that to about 961 moles. 1 ; ¥ The optimization includes operating the said reactor so that the enthalpy change of the said dilute ¢ medium inside and outside of the reactor is within the range extending from £Y °BTU/lb to 110 BTU/lb and maintaining a ratio of 1 above 08 , + for or with respect to the volumetric density of the fluidized bed to the settled volumetric density 7. : B 1 ©*- The process Gy of the claim (?7) where the liquefaction medium includes a gaseous phase and a liquid phase Y where the level of the liquid inside the reactor ranges in the range from 710 to 9650 v by weight total of the dilution medium. 71-1 Process according to claim (16) where the enthalpy change in the extended Y range ranges from about 50 Btu/lb to about ¥ 001 Cia/lb. 1 7 ?- Gay process of protection element (YE) where the yield is drawn at a rate of more than Orv Y lb/hr-ft”. sae Y The aforementioned process includes a gaseous stream passing through a reaction zone and includes monomer 1 in the presence of a catalyst to produce a polymeric yield; withdrawing the said polymeric yield; ¢ and withdrawing the said dilute medium that includes a monomer “Joly” from the said o reaction zone and the mixture of said fluidizing medium with hydrocarbon 1 and polymerizable monomer(s) to form a liquid phase and a gas phase; and return said fluidizing medium back to said reactor; and the improvement includes: A (1) introduction of hydrocarbon said to said fluidizing medium to allow an increase of A in the cooling capacity of the fluidizing medium to a level in the range from 47 Ve BTU/lb to 110 BTU/lb; 11(b) Increasing the rate of withdrawal of the polymer yield above 500 lb/hr - stad \Y Vy | (c) maintaining a percentage higher than +08 for the volumetric density of the saturated layer 0 to the stable bulk density. 1 1?- Process Gy of claim (YA) wherein the liquid phase includes the liquid level in the span of e = 968 by weight based on the total weight of the fluidizing medium. -©0 1 Operation Gag of claim (1) wherein the liquid level is in the range extending from -71 Y by weight based on the total weight of the fluidizing medium. \ \¥- Process according to claim ( \ ) Cua Jl level in the extending range from 1 Y to 9644.7 by weight based on the total weight of the fluidizing medium. From YY by weight based on the total weight of the fluidizing medium. —V¢ 1 process under protection (Y¢) where enthalpy change in the range from 0 Y Btu/lb to 100 Btu/lb. —YO 1 process ag of claim (YE) as the enthalpy change in the range extending from Y 'nbtu/lb to 100 BTU/lb. ©1 - Operation Gig of claim (YE) where the liquid level in the fluidizing medium based on Y is the total weight of the fluidizing medium in the range from Fe to 9650 by weight. fo —¥Y 1 Operation according to protection element (YE) wherein the liquid level in the range from 01 to 7 Y by weight is based on the total weight of the reintroduced stream. YA 1 — process according to protection element (YE) where the liquid level is in the range from YY to 0Y by weight based on the total weight of the reintroduced stream. 1 ¥4— Operation Gi of protection element (YE) where the liquid level in the range YO to Y is 1 by weight based on the reconstituted total weight. 1 - Operation Gig for the protection element (YA), where the liquid level in the dilute medium is based on y the total weight of the quenching medium in the range extending from Ye to 9604 by weight. 1-1 Operation Gi of protection element (YA) wherein the liquid level in the range from 01 to Y 7 by weight is based on the reconstituted total weight. —£Y 1 Operation Gig of protection (YA) where the liquid level in the range extending from YY = Y is by weight based on the reconstituted total weight. 1";- Operation Gag of protection element (YA) in which the liquid level in the range from YO to Y is 5 by weight on the basis of the reconstituted total weight.