US4543399A — Fluidized bed reaction systems

Claim 1

Independent Claim 116 words

In a continuous gas fluidized bed polymerization process for the production of polymer from monomer by continuously passing a gaseous stream comprising said monomer through a fluidized bed reactor in the presence of catalyst under reactive conditions, withdrawing polymeric product and a stream comprising unreacted monomer gases, cooling said stream comprising unreacted monomer gases and returning said cooled stream to said reactor together with sufficient additional monomer to replace that monomer polymerized and withdrawn as product, the improvement which comprises: cooling part or all of said stream comprising unreacted monomer gases to form a mixture comprising a gas phase and a liquid phase and reintroducing said mixture into said reactor wherein said liquid phase is vaporized.

Claim 2

Dependent Claim 116 words

In a continuous gas fluidized bed polymerization process for the production of polymer from monomer by continuously passing a gaseous stream comprising said monomer through a fluidized bed reactor in the presence of catalyst under reactive conditions, withdrawing polymeric product and a stream comprising unreacted monomer gases, cooling said stream comprising unreacted monomer gases and returning said cooled stream to said reactor together with sufficient additional monomer to replace that monomer polymerized and withdrawn as product, the improvement which comprises: cooling part or all of said stream comprising unreacted monomer gases to form a mixture comprising a gas phase and a liquid phase and reintroducing said mixture into said reactor wherein said liquid phase is vaporized.

Claim 3

Dependent Claim 18 words

An improved process according to claim 1 wherein said stream comprising unreacted gases is compressed prior to cooling.

Claim 4

Dependent Claim 29 words

An improved process according to claim 1 wherein means are provided to maintain said liquid phase entrained in said mixture until such time as said liquid phase is vaporized.

Claim 5

Dependent Claim 25 words

An improved process according to claim 1 wherein an inert condensible fluid is present in said mixture to raise the dew point of said mixture.

Claim 6

Dependent Claim 16 words

An improved process according to claim 4 wherein said inert condensible fluid is a saturated hydrocarbon.

Claim 7

Dependent Claim 29 words

An improved process according to claim 1 wherein said liquid phase of said mixture is less than about 20 percent by weight of the total weight of said mixture.

Claim 8

Dependent Claim 29 words

An improved process according to claim 1 wherein said liquid phase of said mixture is less than about 10 percent by weight of the total weight of said mixture.

Claim 9

Dependent Claim 37 words

An improved process according to claim 1 wherein the flow rate of said mixture and the ratio of gas to liquid therein are maintained at levels sufficient to maintain said liquid entrained in said gas until vaporized.

Claim 10

Dependent Claim 78 words

An improved process according to claim 1 wherein said mixture is divided into at least two separate streams at least one of which is introduced into the reactor at a point below the fluidized bed and one or more of said separate streams is optionally introduced into said fluidized bed, provided that the velocity of all gases introduced below said fluidized bed is at least sufficient to support said bed and to maintain it in a fluidized condition.

Claim 11

Dependent Claim 54 words

An improved process according to claim 1 wherein the gas stream flowing upwardly through the fluidized bed is essentially uniform in composition and moving in a manner through said bed such that the entire bed is maintained in a gas fluidized condition and with essentially no dead spaces through which gases do not pass.

Claim 12

Dependent Claim 46 words

An improved process according to claim 1 wherein said additional monomer, added to replace monomer polymerized and withdrawn as product, is introduced into said reactor in liquid form, below the fluidized bed and at or near the point of entry of said mixture into said reactor.

Claim 13

Dependent Claim 34 words

An improved process according to claim 1 wherein said additional monomer added to replace monomer polymerized and withdrawn as product is introduced into said mixture prior to entry of said mixture into said reactor.

Claim 14

Dependent Claim 30 words

An improved process according to claim 1 wherein gas distributor means is provided immediately below the fluidized bed and above the region wherein said mixture is introduced into said reactor.

Claim 15

Dependent Claim 23 words

An improved process according to claim 1 wherein the internal pressure within said reactor is from about 100 psi to about 350 psi.

Claim 16

Dependent Claim 41 words

An improved process according to claim 1 wherein said monomer is an alpha olefin monomer having from two to four carbon atoms alone or in admixture with one or more other alpha olefin monomers having from two to eight carbon atoms.

Claim 17

Dependent Claim 31 words

An improved process according to claim 15, wherein said monomer is ethylene alone or in admixture with one or more other alpha olefin monomers having from two to eight carbon atoms.

Claim 18

Dependent Claim 31 words

An improved process according to claim 15, wherein said monomer is propylene alone or in admixture with one or more other alpha olefin monomers having from two to eight carbon atoms.

Claim 19

Independent Claim 97 words

A method for controlling the temperature of a gas fluidized bed during the production of polymer in a fluidized bed reactor by an exothermic polymerization reaction, which comprises continuously introducing into the bed a stream comprising unreacted monomer gas cooled to below the maximum desired temperature within said bed and simultaneously or separately introducing a stream of liquid into said reactor under conditions such that an essentially uniform mixture of said gas and liquid is introduced into said bed at a level below the region of maximum desired temperature within said reactor wherein said liquid is vaporized.

Claim 20

Independent Claim 97 words

A method for controlling the temperature of a gas fluidized bed during the production of polymer in a fluidized bed reactor by an exothermic polymerization reaction, which comprises continuously introducing into the bed a stream comprising unreacted monomer gas cooled to below the maximum desired temperature within said bed and simultaneously or separately introducing a stream of liquid into said reactor under conditions such that an essentially uniform mixture of said gas and liquid is introduced into said bed at a level below the region of maximum desired temperature within said reactor wherein said liquid is vaporized.

Claim 21

Dependent Claim 140 words

A process for producing polymer from monomer by an exothermic polymerization reaction in a gas fluidized bed reactor having an upper polymerization zone containing a bed of growing polymer particles and a lower gas diffusion zone, which comprises: (1) continuously passing a gaseous stream comprising monomer through said polymerization zone with an upward velocity sufficient to maintain said particles in a suspended and gas fluidized condition; (2) introducing a polymerization catalyst into said polymerization zone; (3) withdrawing polymer product from said polymerization zone; (4) continuously withdrawing a stream of unreacted gases comprising monomer from said polymerization zone, compressing and cooling said stream to a temperature below the dew point of said stream to form a mixture comprising a gas phase and a liquid phase; and (5) continuously introducing said mixture into said polymerization zone wherein said liquid phase is vaporized.

Claim 22

Dependent Claim 140 words

A process for producing polymer from monomer by an exothermic polymerization reaction in a gas fluidized bed reactor having an upper polymerization zone containing a bed of growing polymer particles and a lower gas diffusion zone, which comprises: (1) continuously passing a gaseous stream comprising monomer through said polymerization zone with an upward velocity sufficient to maintain said particles in a suspended and gas fluidized condition; (2) introducing a polymerization catalyst into said polymerization zone; (3) withdrawing polymer product from said polymerization zone; (4) continuously withdrawing a stream of unreacted gases comprising monomer from said polymerization zone, compressing and cooling said stream to a temperature below the dew point of said stream to form a mixture comprising a gas phase and a liquid phase; and (5) continuously introducing said mixture into said polymerization zone wherein said liquid phase is vaporized.

Claim 23

Dependent Claim 24 words

A process according to claim 19 wherein an inert, condensible fluid is present in said mixture to raise the dew point of said mixture.

Claim 24

Dependent Claim 16 words

An improved process according to claim 20 wherein said inert, condensible fluid is a saturated hydrocarbon.

Claim 25

Dependent Claim 28 words

A process according to claim 19 wherein the liquid phase of said mixture is less than about 20 percent by weight of the total weight of said mixture.

Claim 26

Dependent Claim 28 words

A process according to claim 19 wherein the liquid phase of said mixture is less than about 10 percent by weight of the total weight of said mixture.

Claim 27

Dependent Claim 38 words

A process according to claim 19 wherein the flow rate of said mixture and the ratio of gas to liquid in said mixture are maintained at levels sufficient to maintain said liquid entrained in said gas until vaporized.

Claim 28

Dependent Claim 52 words

A process according to claim 19 wherein the gas stream flowing upwardly through the fluidized bed is essentially uniform in composition and moving in a manner through said bed such that the entire bed is maintained in a fluidized condition and with essentially no dead spaces through which gases do not pass.

Claim 29

Dependent Claim 42 words

A process according to claim 19 wherein additional monomer in liquid or gaseous form is added below the polymerization zone and at or near the point of entry of said mixture into said reactor to replace monomer polymerized and withdrawn as product.

Claim 30

Dependent Claim 33 words

A process according to claim 19 wherein additional monomer is added to replace monomer polymerized and withdrawn as product by injection into said mixture prior to entry of said mixture into the reactor.

Claim 31

Dependent Claim 17 words

A process according to claim 19 wherein gas distributor means is provided immediately below said polymerization zone.

Claim 32

Dependent Claim 22 words

A process according to claim 19 wherein the internal pressure within said reactor is from about 100 psi to about 350 psi.

Claim 33

Dependent Claim 44 words

A process according to claim 19 wherein said polymer is produced by reaction of an alpha olefin monomer having from two to four carbon atoms alone or in admixture with one or more other alpha olefin monomers having from two to eight carbon atoms.

Claim 34

Dependent Claim 31 words

An improved process according to claim 30, wherein said monomer is ethylene alone or in admixture with one or more other alpha olefin monomers having from two to eight carbon atoms.

Claim 35

Dependent Claim 31 words

An improved process according to claim 30, wherein said monomer is propylene alone or in admixture with one or more other alpha olefin monomers having from two to eight carbon atoms.

Claim 36

Independent Claim 48 words

A method for controlling the temperature of a fluidized bed during the production of polymers in a gas fluidized bed reactor by an exothermic polymerization reaction which comprises continuously introducing a stream comprising an essentially uniform gas-liquid mixture containing monomer into said bed wherein said liquid is vaporized.

Claim 37

Independent Claim 48 words

A method for controlling the temperature of a fluidized bed during the production of polymers in a gas fluidized bed reactor by an exothermic polymerization reaction which comprises continuously introducing a stream comprising an essentially uniform gas-liquid mixture containing monomer into said bed wherein said liquid is vaporized.

Claim 38

Dependent Claim 134 words

In a continuous gas fluidized bed polymerization process for the production of polymer from monomer by continuously passing a gaseous stream comprising said monomer through a fluidized bed reactor in the presence of catalyst under reactive conditions, withdrawing polymeric product and a stream comprising unreacted monomer gases, cooling said stream comprising unreacted gases and returning said cooled stream to said reactor together with sufficient additional monomer to replace that monomer polymerized and withdrawn as product, the improvement which comprises: cooling part or all of said stream comprising unreacted gases to form a mixture comprising a gas phase and a liquid phase and reintroducing said mixture into said reactor wherein said liquid phase is volatilized; said gaseous stream passing through said fluidized bed reactor at a superficial velocity sufficient to maintain a viable fluidized bed.

Claim 39

Dependent Claim 134 words

In a continuous gas fluidized bed polymerization process for the production of polymer from monomer by continuously passing a gaseous stream comprising said monomer through a fluidized bed reactor in the presence of catalyst under reactive conditions, withdrawing polymeric product and a stream comprising unreacted monomer gases, cooling said stream comprising unreacted gases and returning said cooled stream to said reactor together with sufficient additional monomer to replace that monomer polymerized and withdrawn as product, the improvement which comprises: cooling part or all of said stream comprising unreacted gases to form a mixture comprising a gas phase and a liquid phase and reintroducing said mixture into said reactor wherein said liquid phase is volatilized; said gaseous stream passing through said fluidized bed reactor at a superficial velocity sufficient to maintain a viable fluidized bed.

Claim 40

Dependent Claim 166 words

A process for producing polymer from monomer by an exothermic polymerization reaction in a gas fluidized bed reactor having an upper polymerization zone containing a bed of growing polymer particles and a lower gas diffusion zone, which comprises: (1) continuously passing a gaseous stream comprising monomer through said polymerization zone with an upward velocity sufficient to maintain said particles in a suspended and gas fluidized condition; (2) introducing a polymerization catalyst into said polymerization zone in an inert gas stream at a point 20-40% of the diameter away from the reactor wall and about 5-30% of the height of the bed; (3) withdrawing polymer product from said polymerization zone; (4) continuously withdrawing a stream of unreacted gases comprising monomer from said polymerization zone, compressing and cooling said stream to a temperature below the dew point of said stream to form a mixture comprising a gas phase and a liquid phase; and (5) continuously introducing said mixture into said polymerization zone wherein said liquid phase is vaporized.

Claim 41

Dependent Claim 166 words

A process for producing polymer from monomer by an exothermic polymerization reaction in a gas fluidized bed reactor having an upper polymerization zone containing a bed of growing polymer particles and a lower gas diffusion zone, which comprises: (1) continuously passing a gaseous stream comprising monomer through said polymerization zone with an upward velocity sufficient to maintain said particles in a suspended and gas fluidized condition; (2) introducing a polymerization catalyst into said polymerization zone in an inert gas stream at a point 20-40% of the diameter away from the reactor wall and about 5-30% of the height of the bed; (3) withdrawing polymer product from said polymerization zone; (4) continuously withdrawing a stream of unreacted gases comprising monomer from said polymerization zone, compressing and cooling said stream to a temperature below the dew point of said stream to form a mixture comprising a gas phase and a liquid phase; and (5) continuously introducing said mixture into said polymerization zone wherein said liquid phase is vaporized.

Claim 42

Dependent Claim 173 words

A process for producing polymer from monomer by an exothermic polymerization reaction in a gas fluidized bed reactor having an upper polymerization zone containing a bed of growing polymer particles and a lower gas diffusion zone, which comprises: (1) continuously passing a gaseous stream comprising monomer through said polymerization zone with an upward velocity sufficient to maintain said particles in a suspended and gas fluidized condition; (2) introducing a polymerization catalyst into said polymerization zone; (3) withdrawing polymer product from said polymerization zone; (4) continuously withdrawing a stream of unreacted gases comprising monomer from said polymerization zone, compressing and cooling said stream to a temperature below the dew point of said stream to form a mixture comprising a gas phase and a liquid phase; (5) continuously introducing said mixture into said polymerization zone wherein said liquid phase is vaporized; and (6) controlling the temperature of said mixture so as to maintain constant temperature in said polymerization zone, as the change in polymerization catalyst feed is varied to control the rate of said polymerization.

Claim 43

Dependent Claim 173 words

A process for producing polymer from monomer by an exothermic polymerization reaction in a gas fluidized bed reactor having an upper polymerization zone containing a bed of growing polymer particles and a lower gas diffusion zone, which comprises: (1) continuously passing a gaseous stream comprising monomer through said polymerization zone with an upward velocity sufficient to maintain said particles in a suspended and gas fluidized condition; (2) introducing a polymerization catalyst into said polymerization zone; (3) withdrawing polymer product from said polymerization zone; (4) continuously withdrawing a stream of unreacted gases comprising monomer from said polymerization zone, compressing and cooling said stream to a temperature below the dew point of said stream to form a mixture comprising a gas phase and a liquid phase; (5) continuously introducing said mixture into said polymerization zone wherein said liquid phase is vaporized; and (6) controlling the temperature of said mixture so as to maintain constant temperature in said polymerization zone, as the change in polymerization catalyst feed is varied to control the rate of said polymerization.

Claim 44

Dependent Claim 119 words

In a continuous gas fluidized bed polymerization process for the production of polymer from monomer comprising ethylene and/or propylene by continuously passing a gaseous stream comprising said monomer through a fluidized bed reactor in the presence of catalyst under reactive conditions, withdrawing polymeric product and a stream comprising unreacted gases, comprising monomer, cooling said stream comprising unreacted gases and returning said cooled stream to said reactor together with sufficient additional monomer to replace that monomer polymerized and withdrawn as product, the improvement which comprises: cooling part or all of said stream comprising unreacted gases to form a mixture comprising a gas phase and a liquid phase and reintroducing said mixture into said reactor wherein said liquid phase is vaporized.

Claim 45

Dependent Claim 119 words

In a continuous gas fluidized bed polymerization process for the production of polymer from monomer comprising ethylene and/or propylene by continuously passing a gaseous stream comprising said monomer through a fluidized bed reactor in the presence of catalyst under reactive conditions, withdrawing polymeric product and a stream comprising unreacted gases, comprising monomer, cooling said stream comprising unreacted gases and returning said cooled stream to said reactor together with sufficient additional monomer to replace that monomer polymerized and withdrawn as product, the improvement which comprises: cooling part or all of said stream comprising unreacted gases to form a mixture comprising a gas phase and a liquid phase and reintroducing said mixture into said reactor wherein said liquid phase is vaporized.

Claim 46

Dependent Claim 29 words

An improved process according to claim 37 wherein said monomer comprises ethylene in admixture with one or more other alpha olefin monomers having from two to eight carbon atoms.

Claim 47

Dependent Claim 29 words

An improved process according to claim 37 wherein said monomer comprises propylene in admixture with one or more other alpha olefin monomers having from two to eight carbon atoms.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1988-09-23	1989-03-25	1989-09-24	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1992-09-23	1993-03-25	1993-09-24	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1996-09-23	1997-03-25	1997-09-24	$7700.00	Window Closed / Lapsed

Fluidized bed reaction systems

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