WO2018234350A1 - Procédé de fabrication de polyéthylène à haute densité multimodal - Google Patents

Procédé de fabrication de polyéthylène à haute densité multimodal Download PDF

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Publication number
WO2018234350A1
WO2018234350A1 PCT/EP2018/066347 EP2018066347W WO2018234350A1 WO 2018234350 A1 WO2018234350 A1 WO 2018234350A1 EP 2018066347 W EP2018066347 W EP 2018066347W WO 2018234350 A1 WO2018234350 A1 WO 2018234350A1
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Prior art keywords
catalyst
slurry
reactor
concentration
process according
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PCT/EP2018/066347
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English (en)
Inventor
Johannes Julian Matthias KRUCK
Frans VISSCHER
Eric Johannes Cornelia JANSSEN
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Sabic Global Technologies B.V.
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Publication of WO2018234350A1 publication Critical patent/WO2018234350A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/08—Copolymers of ethene
    • C08L23/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
    • C08L23/0815—Copolymers of ethene with aliphatic 1-olefins

Definitions

  • the present invention relates to a process for the manufacturing of multimodal high density polyethylene (HDPE).
  • HDPE high density polyethylene
  • Bimodal high density polyethylene can be for example produced in a two stage reactor system.
  • the first polymerization stage is performed in a first reactor by mixing catalyst, co-catalyst, diluent, ethylene and optionally co-monomer and hydrogen.
  • catalyst and co-catalyst which are normally of the Ziegler-Natta type,
  • polymerization in the first reactor is performed to obtain HDPE particles having a molecular weight distribution with a relatively low weight median.
  • the slurry from the first reactor can be fed into a second reactor, wherein HDPE having a higher molecular weight and consequently a molecular weight distribution with a higher overall weight median can be produced.
  • the further polymerization can be performed by feeding and mixing diluent, ethylene and optionally co-monomer and hydrogen from the first stage to the second polymerisation stage.
  • the resulting HDPE particles in the second reactor slurry thus obtains a molecular weight distribution that may have two peaks, corresponding to the first median and the second median of the respective stages in the polymerization.
  • the obtained HDPE which was produced in two polymerization reactors and which might result in a two peaked molecular weight distribution, is called bimodal HDPE.
  • the second polymerization stage can actually comprise a plurality of reactors, to produce multimodal HDPE.
  • post processing can be performed in a third reactor, wherein an even higher monomer conversion rate in the slurry can be obtained.
  • Post processing is performed without feeding fresh monomer, as opposed to the first and the polymerization stages wherein fresh monomer is fed.
  • the final polymerization takes place, resulting in a conversion rate of more than 98% of the monomers used.
  • the suspension then flows to a suspension receiver and the suspension leaving the receiver is separated in a decanter centrifuge.
  • the separation in the decanter centrifuge generates two streams: a stream that is essentially liquid, with a small amount of solid polymer fines, and a stream that is essentially a wet solid, with residual amounts of liquid diluent.
  • the solid polymer stream is fed to a fluidized bed dryer.
  • the dried polymer product is HDPE powder which can be pneumatically conveyed by nitrogen to the extrusion section where it can be processed into HDPE pellets.
  • the pellets can be further dried and pneumatically conveyed to homogenization silos.
  • the liquid stream is further subdivided so that part of the stream can be sent back to the second reactor, as is, and part of the liquid stream is sent to a purification section.
  • the liquid stream is heated until most of the diluent is evaporated.
  • the diluent vapors are then sent to a distillation column to separate residual co-monomer from the diluent.
  • Purified, i.e., wax- and (co-)monomer- free diluent is then sent back to the first reactor.
  • the non-evaporated, heavy bottoms of the evaporation step comprise a liquid stream containing dissolved polyethylene wax and solid polyethylene fines.
  • the co-catalyst activates the catalyst in the first reactor, i.e. in the first polymerization stage. Furthermore, the co-catalyst eliminates impurities, such as water and oxygen, from the reaction mixture.
  • the concentration of the co-catalyst is an important factor in the polymerization process. It is known, that with increasing concentration of co-catalyst, as more impurities can be eliminated and more active catalyst sites are formed, the productivity of the catalyst increases and thus the yield of PE.
  • Co-catalysts are efficient chain transfer agents that limit the maximum achievable molar mass in polymerization. This leads to an undesired lower molecular weight in the second polymerization stage, since the co-catalyst is transferred after the first polymerization stage with the slurry from the first reactor into the second reactor for the second polymerization stage.
  • WO2015165861 A1 describes a slurry polymerization process for the preparation of polyethylene in the presence of a Ziegler catalyst and aluminum alkyl in at least one polymerization reactor, in which process suspension medium comprising a
  • concentration of aluminum alkyl is recycled to the polymerization, the concentration of aluminum alkyl in the recycled suspension medium is determined; and the amount of fresh aluminum alkyl fed to the polymerization is adjusted to maintain a targeted aluminum alkyl concentration in the recycled suspension medium.
  • the object is achieved in a process for the manufacturing of high density polyethylene, comprising
  • the method further comprising monitoring a concentration of co-catalyst in the at least one of the second slurry and/or a slurry downstream of the second reactor means (R2);
  • the first and second reactor means allow polymerization under different conditions which can result in a molecular weight distribution having an individual median for each stage.
  • the supply of an amount of a co-catalyst de-activation agent into the second reactor means allows control of the co-catalyst concentration in the second reactor means without affecting the aluminium alkyl concentration in the first reactor means.
  • the second reactor means comprises a cascade of a plurality of reactors for performing the further polymerization.
  • the monitoring a concentration of co-catalyst comprises monitoring a concentration of co-catalyst in the second slurry from a selected reactor of the cascade of the plurality of reactors.
  • the supplying an amount of a co-catalyst deactivation agent into the second reactor means comprises supplying an amount of a co-catalyst de-activation agent into the selected reactor of the cascade of the plurality of reactors.
  • the process further comprises transferring at least part of the second slurry from the second reactor means to third reactor means, and post processing the second slurry to form a third slurry in the third reactor means. With post processing, an even higher monomer conversion rate in the slurry can be obtained.
  • the monitoring a concentration of co-catalyst comprises sampling the slurry via a sampling access opening in the second reactor means. This allows control of the co-catalyst concentration in a short loop with minimal delay.
  • the monitoring a concentration of co-catalyst comprises sampling the second slurry in a transfer means downstream of the second reactor means. This allows easy access to the slurry without modification to the second reactor means.
  • the monitoring a concentration of co-catalyst in the third slurry comprises sampling the slurry in a transfer means downstream of the third reactor means.
  • the concentration can be measured further downstream and need not be measured directly in or from the process of polymerization.
  • the monitoring a concentration of co-catalyst comprises sampling the slurry via a sampling access opening in the third reactor means. This provides an alternative way of measuring the co-catalyst concentration.
  • the monitoring is performed continuously. This allows subsequently the continuous supplying of the de-activation agent and controlling of the co-catalyst concentration. Fast response times can be achieved. In an embodiment the monitoring is performed repeatedly in a predetermined time interval. This provides an alternative way of monitoring, using discrete slurry samples.
  • the monitoring further comprises measuring the co- catalyst concentration.
  • the supplying an amount of co-catalyst de-activation agent dependent on the monitored concentration of co-catalyst comprises controlling a co-catalyst de-activation agent supply means using a controller.
  • the controller can be equipped with an appropriate control function for adequate control of the co-catalyst concentration by supplying the de-activation agent.
  • the co-catalyst deactivation agent is selected from a group of alcohols. These substances are known for efficient breakdown or deactivation of the co-catalyst.
  • the co-catalyst deactivation agent comprises butylated hydroxytoluene (BHT). This is the preferred de-activation agent. BRIEF DESCRIPTION OF THE DRAWINGS
  • Fig. 1 shows a process diagram of a process for manufacturing multimodal high density polyethylene according to the state of the art.
  • Fig. 2 shows a process diagram of a process stage for manufacturing multimodal high density polyethylene according to the invention
  • a two stage cascade process 100 for the polymerization of ethylene is shown, wherein the first reactor R1 may be fed continuously with a first stream 101 mixture of monomers, hydrogen, Ziegler-Natta catalyst/co-catalyst and fresh diluent in an inlet, while a purified diluent (e.g., hexane) stream 102 recycled from the process is fed in another inlet.
  • a purified diluent e.g., hexane
  • Heat of polymerization is removed by flowing slurry through an external cooler C1 , and returning a cooled recycle stream 103 back to reactor.
  • Product from the first reactor initial polymerization is transferred in a slurry stream 104 in a continuous process to the second reactor R2.
  • the slurry stream 104 may flow through a flash unit S1 in order to expel gas trapped in the slurry. Gasses are removed from the top of unit S1 via stream 105, de-gassed slurry is removed from the bottom of unit S1 via de-gassed slurry stream 106. In the second reactor R2 further polymerization is performed by feeding ethylene, monomer, and co-monomer in inlet 107 and recycled fluids to the reactor R2 in inlets 108 and 109. The slurry stream 1 10 from reactor R2 is recycled via cooler C2 back to the reactor R2.
  • bimodal HDPE can be produced, wherein a first mode is produced in reactor R1 , providing HDPE with a first molecular weight density peak in a density distribution curve, and wherein a second mode is produced in reactor R2 providing HDPE with a second molecular weight density peak in the density distribution curve.
  • polymerization of ethylene occurs as an exothermic reaction at pressures in the range between for example from 2 barg to 20 barg, and at temperatures in the range between for example from 70 °C to 90 °C.
  • the heat from the polymerization reaction is removed in coolers C1 , C2 respectively by means of cooling water.
  • the characteristics of the polyethylene are determined amongst others by the catalyst system and by the concentrations of catalyst, co-monomer and hydrogen.
  • the polymerization efficiency of both reactors R1 and R2 may reach values of 98% or higher in terms of ethylene conversion. Co- monomer conversion is typically lower.
  • the slurry from the second reactor R2 can be transferred via slurry stream 1 1 1 to a third reactor R3 where post polymerization can be performed at temperatures and pressures similar to those of R2, thus allowing for continued polymerization and ethylene conversions higher than 98%.
  • the post polymerization can be performed at a temperature of at most 40-90°C and a pressure of 0.3-2.0 barg.
  • the relatively low R3 temperatures employed in this embodiment reduce the rate of all chemical reactions including those that generate polymer (in reactor R3).
  • each stage is connected to a subsequent stage in cascade of stages with reactors R2 for further polymerization, wherein the first reactor R2 receives the first slurry from reactor R1 and delivers slurry to a subsequent stage with another reactor R2.
  • the last stage with a reactor R2 delivers its slurry to post polymerization reactor R3.
  • Each reactor R2 in the cascade can be operated using mutually different production parameters for obtaining corresponding mutually different molecular weight density peaks for each stage.
  • the slurry from the third reactor R3 is transferred via stream 1 13 to a buffer tank S2, and from there to a decanter centrifuge S3 for the separation of liquids and solids.
  • the buffer tank S2 may receive additional streams from other parts of the process, as shown in Fig. 1.
  • the decanter centrifuge S3 the polymer product, in the form of the polymer particles formed during the polymerization process, is separated from the slurry stream 1 14 to form a wet cake.
  • the decanter centrifuge S3 does not remove all solid material from the liquid (at the liquid discharge point), and not all liquid from the solids stream (at the solids discharge point).
  • the wet cake produced by S3 is a relatively concentrated mixture of polymer powder and diluent.
  • the wet cake exiting S3 is transferred via 1 15 to a drying unit S5 where the hexane diluent is further separated from the polymer particles.
  • the hexane diluent extracted by the drying unit may be recycled to the buffer tank S2, in an attempt to remove residual polymer fines from the diluent via a second centrifugation step in S3.
  • the polymer product is discharged from the dryer S5 via 1 18 into a powder treatment vessel S6 where it can be post processed.
  • the post processing may involve processing steps like adding nitrogen, or steam, necessary for obtaining specific end product characteristics.
  • the powder from vessel S6 can for example be discharged via chute 1 19 on a transfer belt X1 .
  • the liquid separated from the polymer product in the decanter centrifuge S3, also referred to as mother liquor 1 16, contains hexane, 1-butene, co-catalyst residues, small solid particles, and other dissolved species.
  • the small solid particles consist of polymeric and non-polymeric material.
  • the polymeric material may have properties equal to the polymer powder, or it may be material with a different molecular weight and/or with a different co-monomer concentration that allows this material to precipitate at a given process temperature downstream of the decanters.
  • the non- polymeric material consists of inorganic solids, such as aluminum oxides and other co- catalyst and catalyst residues.
  • Part of the mother liquor stream 1 16 can be recycled back to reactor R2, via stream 109, while the rest of the mother liquor (stream 1 17) is transferred to a purification unit S4.
  • the purification unit S4 generates three streams.
  • the first stream, stream 102 is purified diluent, essentially free of co-monomer, and free of wax.
  • the second stream, stream 108 is diluent that is free of wax, but that still contains co- monomer.
  • the third stream is polyethylene wax, containing small amounts of polymer fines, small amounts of inorganic solids, and traces of diluent.
  • Ziegler-Natta polymerization of olefins relies on the application of MgCI2 supported TICI3/4 catalysts and aluminium alkyis. Aluminium alkyis serve as co-catalyst for the catalyst as well as scavengers for impurities.
  • oxygen-containing impurities can poison catalysts, and are detrimental for catalyst yields or catalyst selectivities like molar mass or incorporation of co-monomer. Moreover, such impurities may have detrimental effect on the undesired formation of ethane.
  • aluminium alkyis are efficient chain transfer agents that limit the maximum achievable molar mass in polymerization.
  • the mother liquor originating from reactor R2 or the post reactor R3 is recycled via streams 102, 108 to these reactors, potentially accumulating unreacted aluminium alkyis.
  • the molar mass capability and activity of the catalyst may depend on residual active aluminium and may not reach the desired molar masses or activities. While grades with high MFI values might tolerate high aluminium
  • a stage with a reactor R2 is shown, wherein the monitoring of the co-catalyst concentration can be achieved by measuring the concentration of aluminium alkyls in the reactor R2 slurry.
  • liquid and solid phase need to be separated. This can be performed by taking samples from the reactor R2 directly as shown in fig. 2b, from the slurry stream 1 1 1 as shown in fig. 2a, and alternatively (not shown) for example from decanter centrifuge S3 in fig. 1 .
  • samples can be obtained from the reactor R3, and the streams 1 10, 109.
  • the concentration 203b of aluminium alkyls in the samples may then be obtained respectively in the pure liquid phase by calorimetric measurements where t- butanol is added to a sample of the recycled suspension medium, with the heat rise corresponding to the concentration of aluminium a Iky I using a sampling and
  • the slurry samples for obtaining co-catalyst concentration can be obtained from interconnections between the reactors, or from the reactors themselves.
  • the co-catalyst concentration can be measured by an appropriate sensor continuously in the indicated places reactor R2, reactor R3, the streams 1 1 1 , 1 10, 109 and in the decanter centrifuge S3.
  • the de-activating agent, used to adjust the aluminium alkyl concentration in a preferred embodiment may be dosed directly to second reactor 2 as shown in fig. 2 or higher reactor R3 or into the mother liquor stream 109.
  • the deactivating agent flow can be adjusted by a controller 202 in feedback loop 203, 204 to controllable valve 205 such that the residual (reactive) aluminium alkyl concentration is maintained at a desired constant level depending on the required weight distribution properties of the bimodal HDPE to be produced.
  • the valve 205 may be operated intermittently with time intervals defining predetermined quantities of de-activating agent. Alternatively, the valve 205 may be operated continuously providing a controlled flow of de-activating agent.
  • the controller 202 can be a process controller such as a Programmable
  • PLC Logic Controller
  • Polymerization was carried out in a 20 I autoclave reactor. 10 I hexane as diluent was fed to the reactor. The reactor was heated to 85 C. The reactor comprised a headspace to which the reactants were dosed in gaseous form. Ethylene was fed to obtain an ethylene partial pressure in the headspace of the reactor of 1 .0 bar. Hydrogen was fed in such quantity as to ensure a hydrogen to ethylene ratio by volume of 0.005 v/v. A defined amount of a co-catalyst as presented in table 1 was added to the reactor at room temperature.
  • a quantity of a solution of BHT as presented in table 1 was added and the adjusted Al Ti ratio was calculated by taking the BHT amount (AI-BHT/Ti) into account as presented in table 1.
  • a quantity of catalyst slurry containing 10 mg of catalyst was dosed. The temperature was maintained at 78 C, and the pressure was kept constant by feeding ethylene. The hydrogen to ethylene ratio by volume was maintained at 0.005 v/v by feeding hydrogen. The ethylene uptake was monitored over time to calculate the quantity of polymer produced during the reaction. The reaction was stopped after 120 min by depressurizing the reactor to atmospheric conditions, and the reactor contents were cooled to ⁇ 31 °C, after which the reactor contents were passed over a polyamide filter cloth having a pore size of 25 pm. The polymer powder was collected and subsequently dried. The results are summarized in Table 1 .
  • Intrinsic viscosity was determined according to ISO 1628-3 using a Ubbelohde viscometer.
  • co-coatalyst concentration affects achievable molar mass (indicated by intrinsic viscosity) and catalyst yield as demonstrated for a set of experiment (#1 to #3) with otherwise fixed reaction conditions.
  • Table 1 demonstrates that higher amounts of co-catalysts lead to lower molecular weight as indicated by the intrinsic viscosity, examples 1-3.
  • examples 4-5 lead to an increase in molecular weight as demonstrated by the intrinsic viscosities.
  • Comparison of example 2 and 4, which have the same ratio of (AI-BHT) Ti shows that the intrinsic viscosity is higher for example 4.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)

Abstract

L'invention concerne un procédé de fabrication de polyéthylène à haute densité comprenant la réalisation d'une première polymérisation afin de former une première barbotine dans des premiers moyens de réacteur, le transfert d'au moins une partie de la première barbotine du premier réacteur dans des deuxièmes moyens de réacteur, la réalisation d'une autre polymérisation afin de former une deuxième barbotine dans les deuxièmes moyens de réacteur, le transfert d'au moins l'une de la deuxième barbotine et d'une barbotine en aval des deuxièmes moyens de réacteur à des moyens de séparation et la séparation de la barbotine en un produit polymère solide et des liquides dans les moyens de séparation. Le procédé comprend en outre la surveillance d'une concentration de co-catalyseur dans la deuxième barbotine et/ou dans une suspension en aval des deuxièmes moyens de réacteur, et la fourniture d'une quantité d'un agent de désactivation de co-catalyseur dans les deuxièmes moyens de réacteur, la quantité d'agent de désactivation de co-catalyseur étant dépendante de la concentration surveillée de co-catalyseur.
PCT/EP2018/066347 2017-06-20 2018-06-20 Procédé de fabrication de polyéthylène à haute densité multimodal WO2018234350A1 (fr)

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EP17176762.7 2017-06-20

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Cited By (2)

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Publication number Priority date Publication date Assignee Title
WO2021191076A1 (fr) * 2020-03-24 2021-09-30 Basell Polyolefine Gmbh Procédé de suspension pour la préparation de polymères d'éthylène comprenant le traitement conclusif du milieu de suspension
RU2786436C1 (ru) * 2020-03-24 2022-12-21 Базелль Полиолефине Гмбх Суспензионный способ получения этиленовых полимеров, включающий переработку суспензионной среды

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WO2015165861A1 (fr) 2014-04-28 2015-11-05 Basell Polyolefine Gmbh Procédés de régulation d'une alimentation d'alkylaluminium au niveau d'un procédé de polymérisation en suspension
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WO2010136202A1 (fr) 2009-05-28 2010-12-02 Saudi Basic Industries Corporation (Sabic) Procédé de fabrication d'hdpe bimodal avec récupération de cire
US20150353715A1 (en) * 2011-09-19 2015-12-10 Nova Chemicals (International) S.A. Polyethylene compositions and closures made from them
US20130345373A1 (en) * 2012-06-20 2013-12-26 Chevron Phillips Chemical Company Lp Methods for Terminating Olefin Polymerizations
US20140171602A1 (en) * 2012-12-13 2014-06-19 Chevron Phillips Chemical Company, Lp Polyethylene production with multiple polymerization reactors
WO2015165861A1 (fr) 2014-04-28 2015-11-05 Basell Polyolefine Gmbh Procédés de régulation d'une alimentation d'alkylaluminium au niveau d'un procédé de polymérisation en suspension

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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021191076A1 (fr) * 2020-03-24 2021-09-30 Basell Polyolefine Gmbh Procédé de suspension pour la préparation de polymères d'éthylène comprenant le traitement conclusif du milieu de suspension
CN115210268A (zh) * 2020-03-24 2022-10-18 巴塞尔聚烯烃股份有限公司 制备乙烯聚合物的悬浮工艺，包括悬浮介质的后处理
KR20220147149A (ko) * 2020-03-24 2022-11-02 바젤 폴리올레핀 게엠베하 현탁 매질의 워크 업을 포함하는 에틸렌 중합체의 제조를 위한 현탁 프로세스
RU2786436C1 (ru) * 2020-03-24 2022-12-21 Базелль Полиолефине Гмбх Суспензионный способ получения этиленовых полимеров, включающий переработку суспензионной среды
CN115210268B (zh) * 2020-03-24 2023-01-06 巴塞尔聚烯烃股份有限公司 制备乙烯聚合物的悬浮工艺，包括悬浮介质的后处理
KR102504117B1 (ko) * 2020-03-24 2023-02-24 바젤 폴리올레핀 게엠베하 현탁 매질의 워크 업을 포함하는 에틸렌 중합체의 제조를 위한 현탁 프로세스
JP2023508753A (ja) * 2020-03-24 2023-03-03 バーゼル・ポリオレフィン・ゲーエムベーハー 懸濁媒質のワークアップを含むエチレン重合体の製造のための懸濁プロセス
JP7302102B2 (ja) 2020-03-24 2023-07-03 バーゼル・ポリオレフィン・ゲーエムベーハー 懸濁媒質のワークアップを含むエチレン重合体の製造のための懸濁プロセス

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