CA2579754A1 - Energy efficient polyolefin process - Google Patents

Energy efficient polyolefin process Download PDF

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Publication number
CA2579754A1
CA2579754A1 CA002579754A CA2579754A CA2579754A1 CA 2579754 A1 CA2579754 A1 CA 2579754A1 CA 002579754 A CA002579754 A CA 002579754A CA 2579754 A CA2579754 A CA 2579754A CA 2579754 A1 CA2579754 A1 CA 2579754A1
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Prior art keywords
diluent
polyolefin
polymerization reactor
slurry
monomer
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CA002579754A
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French (fr)
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CA2579754C (en
Inventor
Robert R. Mcelvain
John D. Hottovy
Donald W. Verser
David H. Burns
John H. Tait
Richard Peacock
James E. Hein
Ralph W. Romig
Carl W. Fenderson
Scott E. Kufeld
Anurag Gupta
Dale A. Zellers (Deceased)
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Chevron Phillips Chemical Co LP
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0006—Controlling or regulating processes
    • B01J19/0013—Controlling the temperature of the process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/18—Stationary reactors having moving elements inside
    • B01J19/1812—Tubular reactors
    • B01J19/1837—Loop-type reactors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/24—Stationary reactors without moving elements inside
    • B01J19/2455—Stationary reactors without moving elements inside provoking a loop type movement of the reactants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/0015—Feeding of the particles in the reactor; Evacuation of the particles out of the reactor
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2/00—Processes of polymerisation
    • C08F2/01—Processes of polymerisation characterised by special features of the polymerisation apparatus used
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F6/00—Post-polymerisation treatments
    • C08F6/001—Removal of residual monomers by physical means
    • C08F6/003—Removal of residual monomers by physical means from polymer solutions, suspensions, dispersions or emulsions without recovery of the polymer therefrom
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/00008—Controlling the process
    • B01J2208/00017—Controlling the temperature
    • B01J2208/00106—Controlling the temperature by indirect heat exchange
    • B01J2208/00168—Controlling the temperature by indirect heat exchange with heat exchange elements outside the bed of solid particles
    • B01J2208/00212—Plates; Jackets; Cylinders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/00743—Feeding or discharging of solids
    • B01J2208/00752—Feeding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00002—Chemical plants
    • B01J2219/00004—Scale aspects
    • B01J2219/00006—Large-scale industrial plants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/02—Apparatus characterised by their chemically-resistant properties
    • B01J2219/0204—Apparatus characterised by their chemically-resistant properties comprising coatings on the surfaces in direct contact with the reactive components
    • B01J2219/0236—Metal based
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F110/00—Homopolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F110/02—Ethene

Abstract

A manufacturing process for producing polyolefin, having a feed system, a reactor system including a polymerization reactor, a diluent/monomer recovery system, a fractionation system, and an extrusion/loadout system having an extruder. The manufacturing process is configured to consume less than about 445 kilowatt-hours of electricity per metric ton of polyolefin produced.

Claims (39)

1. A manufacturing system for producing polyolefin, comprising:
a feed system for a polymerization reactor;

a reactor system comprising the polymerization reactor, wherein the polymerization reactor is configured to polymerize olefin monomer in the presence of a catalyst and diluent to form a slurry comprising polyolefin particles and diluent;
a diluent/monomer recovery system configured to separate a majority of the diluent from the slurry discharged from the polymerization reactor;
a fractionation system configured to process a portion of the diluent discharged from the diluent/monomer recovery system and to provide recovered diluent substantially free of olefin monomer; and an extrusion/loadout system having an extruder/pelletizer configured to extrude and pelletize polyolefin particles recovered from the slurry in the diluent/monomer recovery system, wherein the manufacturing system is configured to consume less than about 445 kilowatt-hours of energy per metric ton of polyolefin produced based on consumption of electricity, steam, and fuel gas.
2. The method of claim 1, wherein the manufacturing system is configured to produce at least about 600 million pounds of polyolefin per year.
3. A manufacturing system for producing polyolefin, comprising:
a feed system for a polymerization reactor;
a polyolefin reactor system having the polymerization reactor;
a diluent/monomer recovery system configured to receive a slurry discharged from the polymerization reactor, wherein the slurry comprises polyolefin particles and diluent;
a fractionation system configured to process a portion of the diluent recovered in the diluent/monomer recovery system; and an extrusion/loadout system having an extruder/pelletizer configured to pelletize the polyolefin particles recovered in the diluent/monomer recovery system, wherein the manufacturing system is configured to consume less than 325 kilowatt-hours of electricity per metric ton of polyolefin produced.
4. The manufacturing system of claim 3, wherein the feed system has six or fewer feed treaters configured to remove catalysts poisons from feed streams of the polymerization reactor.
5. The manufacturing system of claim 3, wherein the polymerization reactor comprises a slurry circulation pump having guide vanes.
6. The manufacturing system of claim 3, wherein the polyolefin reactor system comprises a coolant pump configured to circulate water through a jacket of the polymerization reactor, wherein an outlet temperature of the water exiting the jacket is about 15 °F to about 45 °F greater than an inlet temperature of the water entering the jacket.
7. The manufacturing system of claim 3, wherein the polymerization reactor comprises aluminum.
8. The manufacturing system of claim 3, wherein the polymerization reactor comprises a continuous takeoff configured to discharge the slurry comprising polyolefin particles and diluent.
9. The manufacturing system of claim 3, wherein the diluent/monomer recovery system comprises a high-pressure separation vessel without an associated flash-gas compressor.
10. The manufacturing system of claim 3, wherein the diluent/monomer recovery system comprises a high-pressure flash vessel and a purge column but does not comprise a low-pressure flash vessel or a low-pressure flash compressor.
11. The manufacturing system of claim 3, wherein in the extrusion/loadout system is configured to receive the polyolefin particles discharged from a purge column in the diluent/monomer recovery without intermediate holdup of the polyolefin particles.
12. The manufacturing system of claim 3, wherein the extrusion/loadout system comprises a pellet water pump configured to facilitate transport of polyolefin pellets discharged from the extruder/pelletizer to a pellet silo.
13. A manufacturing system for producing polyolefin, comprising:
a feed system;
a polyolefin reactor system having a polymerization reactor;
a diluent/monomer recovery system configured to process an effluent discharged from the polymerization reactor, wherein the effluent comprises polyolefin particles and diluent;

a fractionation system configured to process a portion of the diluent; and an extrusion/loadout system having an extruder, wherein the manufacturing system is configured to consume less than 144 kilogram of steam per metric ton of polyolefin produced.
14. The manufacturing system of claim 13, wherein the feed system comprises a mass meter configured to measure a flow rate of ethylene fed to the polymerization reactor.
15. The manufacturing system of claim 13, wherein the diluent/monomer recovery system is configured to facilitate recycle of at least about 80 weight % of diluent recovered in the diluent/monomer recovery system to the polymerization reactor without fractionation.
16. A manufacturing system for producing polyolefin, comprising:
a feed system;
a polyolefin reactor system having a polymerization reactor;
a diluent/monomer recovery system;
a fractionation system; and an extrusion/loadout system having an extruder, wherein the manufacturing system is configured to consume less than 2.8 kilograms of fuel gas per metric ton of polyolefin produced.
17. The manufacturing system of claim 16, wherein the feed system comprises a catalyst activator comprising an inner vessel having a nominal inner diameter in the range of about 48 inches to about 72 inches.
18. The manufacturing system of claim 16, wherein the feed system comprises a feed treater configured to utilize nitrogen during a regeneration cycle and to discharge substantially-clean nitrogen to the atmosphere during a cool-down portion of the regeneration cycle.
19. A manufacturing system for producing polyolefin, comprising:
a feed system;
a polyolefin reactor system having a polymerization reactor;
a diluent/monomer recovery system;

a fractionation system; and an extrusion/loadout system having an extruder, wherein the manufacturing system is configured to maintain losses of nitrogen at less than 26 normal cubic meters of nitrogen per metric ton of polyolefin produced.
20. A manufacturing system for producing polyolefin, comprising:
a feed system;
a reactor system having a polymerization reactor configured to employ isobutane as a diluent;
a diluent/monomer recovery system;
a fractionation system; and an extrusion/loadout system having an extruder, wherein the manufacturing system is configured to maintain losses of the isobutane at less than 1.7 kilograms of isobutane per metric ton of polyolefin produced.
21. A method for operating a polyolefin manufacturing process, comprising:
feeding a monomer, a diluent, and a catalyst to a polymerization reactor;
polymerizing the monomer in the polymerization reactor to form polyolefin particles;
discharging a slurry from the polymerization reactor, wherein the slurry comprises monomer, diluent, and polyolefin particles;
recovering polyolefin particles from the slurry by separating at least a majority of the diluent from the slurry;
recycling a first portion of the separated diluent to the polymerization reactor without fractionating the first portion;

fractionating a second portion of the separated diluent to provide diluent substantially free of monomer;
extruding and pelletizing the recovered polyolefin particles to form polyolefin pellets;
transporting polyolefin pellets to a load-out area; and consuming less than about 445 kilowatt-hours of energy per metric ton of polyolefin produced based on consumption of electricity, steam, and fuel gas.
22. The method of claim 21, comprising producing at least about 600 million pounds of polyolefin pellets per year.
23. A method for operating a polyolefin manufacturing process, comprising:
feeding a monomer, a diluent, and a catalyst to a polymerization reactor;
polymerizing the monomer in the polymerization reactor to form polyolefin particles;

discharging a slurry from the polymerization reactor, wherein the slurry comprises monomer, diluent, and polyolefin particles;
recovering polyolefin particles from the slurry by separating at least a majority of the diluent from the slurry;
recycling a first portion of the separated diluent to the polymerization reactor without fractionating the first portion;
fractionating a second portion of the separated diluent to provide diluent substantially free of monomer;
extruding and pelletizing the recovered polyolefin particles to form polyolefin pellets;
transporting polyolefin pellets to a load-out area; and consuming less than 325 kilowatt-hours of electricity per metric ton of polyolefin pellets produced.
24. The method of claim 23, comprising operating a feed treater as a spare for both removing catalyst poisons in monomer fed to the polymerization reactor and for removing catalyst poisons in diluent fed to the polymerization reactor.
25. The method of claim 23, comprising circulating a coolant through a jacket of the polymerization reactor and maintaining a temperature increase of the coolant through the jacket in the range of about 15 °F to about 45 °F.
26. The method of claim 23, wherein discharging a slurry from the polymerization reactor comprises substantially continuously discharging the slurry from the polymerization reactor.
27. The method of claim 23, wherein separating diluent from the slurry comprises flashing diluent from the slurry and condensing the flashed diluent without compression.
28. The method of claim 23, wherein separating the diluent and separating the polyolefin particles comprise:
subjecting the slurry to a high-pressure flash to generate a flash stream comprising diluent and a solids stream comprising polyolefin particles and residual diluent; and purging the solids stream to remove residual diluent from the polyolefin particles, wherein the solids stream is not subjected to an intermediate low-pressure flash.
29. The method of claim 23, comprising transporting the polyolefin particles separated from the slurry to an extruder feed tank without substantial intermediate hold-up of the transported polyolefin particles.
30. The method of claim 23, wherein transporting polyolefin pellets to a load-out area comprising transporting the polyolefin pellets to a pellet silo via a pellet water pump disposed at a discharge of an upstream extruder/pelletizer.
31. A method for operating a polyolefin manufacturing process, comprising:
feeding a monomer, a diluent, and a catalyst to a polymerization reactor;
polymerizing the monomer in the polymerization reactor to form polyolefin particles;
discharging a slurry from the polymerization reactor, wherein the slurry comprises monomer, diluent, and polyolefin particles;
recovering polyolefin particles from the slurry by separating at least a majority of the diluent from the slurry;
recycling a first portion of the separated diluent to the polymerization reactor without fractionating the first portion;
fractionating a second portion of the separated diluent to provide diluent substantially free of monomer;

extruding and pelletizing the recovered polyolefin particles to form polyolefin pellets;

transporting polyolefin pellets to a load-out area; and consuming less than 144 kilograms of steam per metric ton of polyolefin pellets produced.
32. The method of claim 31, comprising measuring a flow rate of ethylene monomer fed to the polymerization reactor with a mass meter.
33. The method of claim 31, wherein the first portion of separated diluent comprises at least about 80 weight % of the diluent discharge in the slurry from the polymerization reactor.
34. A method for operating a polyolefin manufacturing process, comprising:
feeding a monomer, a diluent, and a catalyst to a polymerization reactor;
polymerizing the monomer in the polymerization reactor to form polyolefin particles;
discharging a slurry from the polymerization reactor, wherein the slurry comprises monomer, diluent, and polyolefin particles;
recovering polyolefin particles from the slurry by separating at least a majority of the diluent from the slurry;
recycling a first portion of the separated diluent to the polymerization reactor without fractionating the first portion;
fractionating a second portion of the separated diluent to provide diluent substantially free of monomer;
extruding and pelletizing the recovered polyolefin particles to form polyolefin pellets;
transporting polyolefin pellets to a load-out area; and consuming less than 2.8 kilograms of fuel gas per metric ton of polyolefin pellets produced.
35. The method of claim 34, comprising activating the catalyst in a catalyst activator prior to feeding the catalyst to the polymerization reactor, wherein the catalyst activator comprises an inner vessel having a nominal inner diameter in the range of about 48 inches to about 72 inches.
36. The manufacturing system of claim 34, wherein feeding diluent to the polymerization reactor comprises removing catalyst poisons from the diluent in a feed treater.
37. The method of claim 36, comprising regenerating the feed treater with nitrogen and discharging substantially-clean nitrogen to the atmosphere from the feed treater during the regeneration.
38. A method for operating a polyolefin manufacturing process, comprising:
feeding a monomer, a diluent, and a catalyst to a polymerization reactor;
polymerizing the monomer in the polymerization reactor to form polyolefin particles;

discharging a slurry from the polymerization reactor, wherein the slurry comprises monomer, diluent, and polyolefin particles;
recovering polyolefin particles from the slurry by separating at least a majority of the diluent from the slurry;
recycling a first portion of the separated diluent to the polymerization reactor without fractionating the first portion;
fractionating a second portion of the separated diluent to provide diluent substantially free of monomer;
extruding and pelletizing the recovered polyolefin particles to form polyolefin pellets;
transporting polyolefin pellets to a load-out area; and maintaining losses of nitrogen in the polyolefin manufacturing system at less than 26 normal cubic meters of nitrogen per metric ton of polyolefin pellets produced.
39. A method for operating a polyolefin manufacturing process, comprising:
feeding a monomer, a diluent, and a catalyst to a polymerization reactor, wherein the diluent comprises isobutane;
polymerizing the monomer in the polymerization reactor to form polyolefin particles;
discharging a slurry from the polymerization reactor, wherein the slurry comprises monomer, diluent, and polyolefin particles;
recovering polyolefin particles from the slurry by separating at least a majority of the diluent from the slurry;
recycling a first portion of the separated diluent to the polymerization reactor without fractionating the first portion;
fractionating a second portion of the separated diluent to provide diluent substantially free of monomer;
extruding and pelletizing the recovered polyolefin particles to form polyolefin pellets;

transporting polyolefin pellets to a load-out area; and maintaining losses of the isobutane in the polyolefin manufacturing system at less than 1.7 kilograms of isobutane per metric ton of polyolefin pellets produced.
CA2579754A 2004-08-27 2005-08-26 Energy efficient polyolefin process Active CA2579754C (en)

Applications Claiming Priority (3)

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US60494804P 2004-08-27 2004-08-27
US60/604,948 2004-08-27
PCT/US2005/030528 WO2006026493A1 (en) 2004-08-27 2005-08-26 Energy efficient polyolefin process

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US (7) US8017701B2 (en)
EP (3) EP2289952B2 (en)
CN (2) CN102615734B (en)
BR (1) BRPI0514170B1 (en)
CA (1) CA2579754C (en)
DK (1) DK2289952T3 (en)
ES (3) ES2416314T3 (en)
HK (1) HK1109411A1 (en)
MX (1) MX2007002216A (en)
PL (1) PL1791875T3 (en)
WO (1) WO2006026493A1 (en)

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