US5436304A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Process for polymerizing monomers in fluidized beds
Assignee: ExxonMobil Chemical Patents Inc
•
Filing: 1994-10-03
•
Granted: 1995-07-25
•
Expires: 2014-10-03
Abstract
Abstract The invention is directed toward polymerizing or copolymerizing alpha-olefins either alone or in combination with one or more other alpha-olefins in a gas phase reactor having a fluidized bed and a fluidizing medium such that the fluidizing medium entering the reactor comprises a gas and a liquid phase.
Inventors
- 👤 John R. Griffin
- 👤 Marc L. DeChellis
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 06:43
CPC Classifications
C; C08; C08F; C08F210/00; C08F210/16; C08F10/00; Y; Y10; Y10S; Y10S526/00; Y10S526/901
Claims Analysis
Total Claims: 93
Claim 1
Independent Claim
89 words
A process for polymerizing alpha-olefin(s) in a gas phase reactor having a fluidized bed and a fluidizing medium wherein the fluidizing medium serves to control the cooling capacity of said reactor, the process comprising employing in the fluidizing medium a level of liquid entering the reactor which is greater than 17.4 to 50 weight percent based on the total weight of the fluidizing medium and wherein the bulk density function (Z) is maintained at a value equal to or greater than the calculated limit of the bulk density function.
Claim 2
Dependent Claim
89 words
A process for polymerizing alpha-olefin(s) in a gas phase reactor having a fluidized bed and a fluidizing medium wherein the fluidizing medium serves to control the cooling capacity of said reactor, the process comprising employing in the fluidizing medium a level of liquid entering the reactor which is greater than 17.4 to 50 weight percent based on the total weight of the fluidizing medium and wherein the bulk density function (Z) is maintained at a value equal to or greater than the calculated limit of the bulk density function.
Claim 3
Dependent Claim
28 words
The process in accordance with claim 1 wherein the level of liquid is greater than about 20 weight percent based on the total weight of the fluidizing medium.
Claim 4
Dependent Claim
29 words
The process in accordance with claim 1 wherein the level of liquid is greater than about 25 weight percent liquid based on the total weight of the fluidizing medium.
Claim 5
Dependent Claim
38 words
The process in accordance with claim 1 wherein the level of liquid in the fluidizing medium based on the total weight of the fluidizing medium is in the range of between about 30 to about 50 weight percent.
Claim 6
Dependent Claim
22 words
The process in accordance with claim 1 wherein polymer product is withdrawn at a rate greater than about 500 lb/hr-ft 2 .
Claim 7
Dependent Claim
27 words
The process in accordance with claim 1 wherein the level of liquid is greater than 18 weight percent based on the total weight of the fluidizing medium.
Claim 8
Dependent Claim
22 words
The process in accordance with claim 1 wherein the calculated limit is in the range of from about 0.2 to about 0.7.
Claim 9
Dependent Claim
22 words
The process in accordance with claim 1 wherein the calculated limit is in the range of from about 0.3 to about 0.6.
Claim 10
Dependent Claim
22 words
The process in accordance with claim 1 wherein the calculated limit is in the range of from about 0.4 to about 0.6.
Claim 11
Dependent Claim
16 words
The process in accordance with claim 1 wherein the calculated limit is greater than about 0.4.
Claim 12
Dependent Claim
24 words
The process in accordance with claim 1 wherein the bulk density function (Z) is greater than the calculated limit of the bulk density function.
Claim 13
Dependent Claim
26 words
The process in accordance with claim 1 wherein the bulk density function (Z) is greater than 1% above the calculated limit of the bulk density function.
Claim 14
Dependent Claim
89 words
The process in accordance with claim 1 wherein said fluidizing medium comprises: i) butene-1 and ethylene at a molar ratio of from about 0.001 to about 0.60 or 4-methyl-pentene-1 and ethylene at a molar ratio of from about 0.001 to about 0.50 or hexene-1 and ethylene at a molar ratio of from about 0.001 to about 0.30 or octene-1 and ethylene at a molar ratio of from about 0.001 to about 0.10; ii) a condensable fluid comprising from about 1.5 to about 20 mole percent of the fluidizing medium.
Claim 15
Dependent Claim
89 words
The process in accordance with claim 1 wherein said fluidizing medium comprises: i) butene-1 and ethylene at a molar ratio of from about 0.001 to about 0.60 or 4-methyl-pentene-1 and ethylene at a molar ratio of from about 0.001 to about 0.50 or hexene-1 and ethylene at a molar ratio of from about 0.001 to about 0.30 or octene-1 and ethylene at a molar ratio of from about 0.001 to about 0.10; ii) a condensable fluid comprising from about 1.5 to about 30 mole percent of the fluidizing medium.
Claim 16
Dependent Claim
89 words
The process in accordance with claim 1 wherein said fluidizing medium comprises: i) butene-1 and ethylene at a molar ratio of from about 0.001 to about 0.30 or 4-methyl-pentene-1 and ethylene at a molar ratio of from about 0.001 to about 0.25 or hexene-1 and ethylene at a molar ratio of from about 0.001 to about 0.15 or octene-1 and ethylene at a molar ratio of from about 0.001 to about 0.05; ii) a condensable fluid comprising from about 5 to about 40 mole percent of the fluidizing medium.
Claim 17
Dependent Claim
105 words
A process for polymerizing alpha-olefin(s) in a gas phase reactor having a fluidized bed and a fluidizing medium to produce a polymer product having a density in the range of 0.90 g/cc to about 0.939 g/cc, said process comprising operating said reactor such that the enthalpy change of said fluidizing medium entering and exiting the reactor is greater than 42 Btu/lb to about 110 Btu/lb and wherein the bulk density function (Z) is maintained at a value equal to or greater than the calculated limit of the bulk density function and wherein the polymer product is withdrawn at a rate above 500 lb/hr-ft 2 .
Claim 18
Dependent Claim
105 words
A process for polymerizing alpha-olefin(s) in a gas phase reactor having a fluidized bed and a fluidizing medium to produce a polymer product having a density in the range of 0.90 g/cc to about 0.939 g/cc, said process comprising operating said reactor such that the enthalpy change of said fluidizing medium entering and exiting the reactor is greater than 42 Btu/lb to about 110 Btu/lb and wherein the bulk density function (Z) is maintained at a value equal to or greater than the calculated limit of the bulk density function and wherein the polymer product is withdrawn at a rate above 500 lb/hr-ft 2 .
Claim 19
Dependent Claim
42 words
The process in accordance with claim 16 wherein the fluidizing medium comprises a gas and a liquid phase wherein the level of liquid entering the reactor is greater than about 20 weight percent based on the total weight of the fluidizing medium.
Claim 20
Dependent Claim
24 words
The process in accordance with claim 16 wherein the enthalpy change is in the range of between about 50 Btu/lb to about 100 Btu/Ib.
Claim 21
Dependent Claim
21 words
The process in accordance with claim 16 wherein the product is withdrawn at a rate above about 600 lb/hr-ft 2 .
Claim 22
Dependent Claim
42 words
The process in accordance with claim 16 wherein the fluidizing medium comprises a gas and a liquid phase wherein the level of liquid entering the reactor is greater than about 18 weight percent based on the total weight of the fluidizing medium.
Claim 23
Dependent Claim
22 words
The process in accordance with claim 16 wherein the calculated limit is in the range of from about 0.2 to about 0.7.
Claim 24
Dependent Claim
22 words
The process in accordance with claim 16 wherein the calculated limit is in the range of from about 0.3 to about 0.6.
Claim 25
Dependent Claim
24 words
The process in accordance with claim 16 wherein the bulk density function (Z) is greater than the calculated limit of the bulk density function.
Claim 26
Dependent Claim
26 words
The process in accordance with claim 16 wherein the bulk density function (Z) is greater than 1% above the calculated limit of the bulk density function.
Claim 27
Dependent Claim
102 words
A process for polymerizing alpha-olefin(s) in a gas phase reactor having a fluidized bed and a fluidizing medium having a gas phase and a liquid phase entering the reactor, said process comprising: a) controlling the cooling capacity of said fluidizing medium by controlling the ratio of said gas phase to said liquid phase wherein the liquid phase comprises a level of liquid greater than 17.4 to 50 weight percent based on the total weight of the fluidizing medium; and b) maintaining the bulk density function (Z) at a value greater than or equal to the calculated limit of the bulk density function.
Claim 28
Dependent Claim
102 words
A process for polymerizing alpha-olefin(s) in a gas phase reactor having a fluidized bed and a fluidizing medium having a gas phase and a liquid phase entering the reactor, said process comprising: a) controlling the cooling capacity of said fluidizing medium by controlling the ratio of said gas phase to said liquid phase wherein the liquid phase comprises a level of liquid greater than 17.4 to 50 weight percent based on the total weight of the fluidizing medium; and b) maintaining the bulk density function (Z) at a value greater than or equal to the calculated limit of the bulk density function.
Claim 29
Dependent Claim
28 words
The process in accordance with claim 25 wherein the bulk density function (Z) is maintained at a value greater than the calculated limit of the bulk density function.
Claim 30
Dependent Claim
16 words
The process in accordance with claim 25 wherein the calculated limit is greater than about 0.4.
Claim 31
Dependent Claim
21 words
The process in accordance with claim 25 wherein the calculated limit is in the range of about 0.2 to about 0.7.
Claim 32
Dependent Claim
21 words
The process in accordance with claim 25 wherein the calculated limit is in the range of about 0.3 to about 0.6.
Claim 33
Dependent Claim
26 words
The process in accordance with claim 25 wherein the bulk density function (Z) is greater than 1% above the calculated limit of the bulk density function.
Claim 34
Dependent Claim
26 words
The process in accordance with claim 25 wherein the bulk density function (Z) is greater than 2% above the calculated limit of the bulk density function.
Claim 35
Dependent Claim
31 words
The process in accordance with claim 25 wherein the liquid phase comprises a level of liquid greater than about 18 weight percent based on the total weight of the fluidizing medium.
Claim 36
Dependent Claim
31 words
The process in accordance with claim 25 wherein the liquid phase comprises a level of liquid greater than about 20 weight percent based on the total weight of the fluidizing medium.
Claim 37
Dependent Claim
31 words
The process in accordance with claim 25 wherein the liquid phase comprises a level of liquid greater than about 25 weight percent based on the total weight of the fluidizing medium.
Claim 38
Dependent Claim
160 words
A continuous process for increasing reactor productivity of a gas phase polymerization reactor having a fluidizing medium and fluidized bed, said process comprising passing a gaseous stream comprising monomer through a reaction zone in the presence of a catalyst to produce a polymeric product, withdrawing said polymeric product, withdrawing said fluidizing medium comprising unreacted monomer from said reaction zone, mixing said fluidizing medium with hydrocarbon and polymerizable monomer(s) to form a liquid and a gas phase, and recycling said fluidizing medium to said reactor, the process comprising: a) introducing said hydrocarbon into said fluidizing medium to permit an increase in the cooling capacity of the fluidizing medium above 42 Btu/lb to 110 Btu/lb; b) increasing the rate of withdrawal of polymer product to above at least about 500 lb/hr-ft 2 ; c) calculating a bulk density function limit; and d) maintaining a bulk density function (Z) value greater than or equal to the calculated limit of the bulk density function.
Claim 39
Dependent Claim
160 words
A continuous process for increasing reactor productivity of a gas phase polymerization reactor having a fluidizing medium and fluidized bed, said process comprising passing a gaseous stream comprising monomer through a reaction zone in the presence of a catalyst to produce a polymeric product, withdrawing said polymeric product, withdrawing said fluidizing medium comprising unreacted monomer from said reaction zone, mixing said fluidizing medium with hydrocarbon and polymerizable monomer(s) to form a liquid and a gas phase, and recycling said fluidizing medium to said reactor, the process comprising: a) introducing said hydrocarbon into said fluidizing medium to permit an increase in the cooling capacity of the fluidizing medium above 42 Btu/lb to 110 Btu/lb; b) increasing the rate of withdrawal of polymer product to above at least about 500 lb/hr-ft 2 ; c) calculating a bulk density function limit; and d) maintaining a bulk density function (Z) value greater than or equal to the calculated limit of the bulk density function.
Claim 40
Dependent Claim
15 words
The process in accordance with claim 35 wherein the calculated limit is greater than 0.4.
Claim 41
Dependent Claim
21 words
The process in accordance with claim 35 wherein the calculated limit is in the range of about 0.2 to about 0.7.
Claim 42
Dependent Claim
30 words
The process in accordance with claim 35 wherein the liquid phase comprises a level of liquid greater than 20 weight percent based on the total weight of the fluidizing medium.
Claim 43
Dependent Claim
24 words
The process in accordance with claim 35 wherein the bulk density function (Z) is greater than the calculated limit of the bulk density function.
Claim 44
Dependent Claim
84 words
A process or polymerizing alpha-olefin(s) in a gas phase reactor having a fluidized bed and a fluidizing medium for producing a polymer product having a density greater than about 0.940 g/cc, the processing comprising operating said reactor such that the enthalpy change of said fluidizing medium entering and exiting the reactor is greater than 67 Btu/lb to 110 Btu/lb and wherein the bulk density function (Z) is maintained at a value equal to or greater than the calculated limit of the bulk density function.
Claim 45
Dependent Claim
84 words
A process or polymerizing alpha-olefin(s) in a gas phase reactor having a fluidized bed and a fluidizing medium for producing a polymer product having a density greater than about 0.940 g/cc, the processing comprising operating said reactor such that the enthalpy change of said fluidizing medium entering and exiting the reactor is greater than 67 Btu/lb to 110 Btu/lb and wherein the bulk density function (Z) is maintained at a value equal to or greater than the calculated limit of the bulk density function.
Claim 46
Dependent Claim
44 words
The process in accordance with claim 40 wherein the fluidizing medium comprises a gas and a liquid phase wherein the level of liquid added to the reactor is greater than 20 to 50 weight percent based on the total weight of the fluidizing medium.
Claim 47
Dependent Claim
24 words
The process in accordance with claim 40 wherein the enthalpy change is in the range of between about 75 Btu/lb to about 110 Btu/lb.
Claim 48
Dependent Claim
21 words
The process in accordance with claim 40 wherein the product is withdrawn at a rate above about 500 lb/hr-ft 2 .
Claim 49
Dependent Claim
45 words
The process in accordance with claim 40 wherein the fluidizing medium comprises a gas and a liquid phase wherein the level of liquid added to the reactor is greater than 22 to about 35 weight percent based on the total weight of the fluidizing medium.
Claim 50
Dependent Claim
24 words
The process in accordance with claim 40 wherein the bulk density function (Z) is greater than the calculated limit of the bulk density function.
Claim 51
Dependent Claim
22 words
The process in accordance with claim 40 wherein the calculated limit is in the range of from about 0.2 to about 0.7.
Claim 52
Dependent Claim
22 words
The process in accordance with claim 40 wherein the calculated limit is in the range of from about 0.3 to about 0.6.
Claim 53
Dependent Claim
22 words
The process in accordance with claim 40 wherein the calculated limit is in the range of from about 0.4 to about 0.6.
Claim 54
Dependent Claim
16 words
The process in accordance with claim 40 wherein the calculated limit is greater than about 0.4.
Claim 55
Dependent Claim
26 words
The process in accordance with claim 45 wherein the bulk density function (Z) is greater than 1% above the calculated limit of the bulk density function.
Claim 56
Dependent Claim
121 words
A process for polymerizing alpha-olefin(s) in a gas phase reactor having a fluidizing bed and a fluidizing medium having a gas phase and a liquid phase entering the reactor, said process comprising: a) controlling the cooling capacity of said fluidizing medium by controlling the ratio of said gas phase to said liquid phase wherein the liquid phase comprises a level of liquid greater than 17.4 to 50 weight percent based on the total weight of the fluidizing medium; b) calculating a bulk density function limit; c) monitoring a bulk density function (Z); and d) adjusting the bulk density function (Z) to maintain the bulk density function (Z) at a value greater than or equal to the calculated bulk density function limit.
Claim 57
Dependent Claim
121 words
A process for polymerizing alpha-olefin(s) in a gas phase reactor having a fluidizing bed and a fluidizing medium having a gas phase and a liquid phase entering the reactor, said process comprising: a) controlling the cooling capacity of said fluidizing medium by controlling the ratio of said gas phase to said liquid phase wherein the liquid phase comprises a level of liquid greater than 17.4 to 50 weight percent based on the total weight of the fluidizing medium; b) calculating a bulk density function limit; c) monitoring a bulk density function (Z); and d) adjusting the bulk density function (Z) to maintain the bulk density function (Z) at a value greater than or equal to the calculated bulk density function limit.
Claim 58
Dependent Claim
26 words
The process in accordance with claim 51 wherein the bulk density function (Z) is maintained at a value greater than the calculated bulk density function limit.
Claim 59
Dependent Claim
16 words
The process in accordance with claim 51 wherein the calculated limit is greater than about 0.4.
Claim 60
Dependent Claim
22 words
The process in accordance with claim 51 wherein the calculated limit is in the range of from about 0.2 to about 0.7.
Claim 61
Dependent Claim
22 words
The process in accordance with claim 51 wherein the calculated limit is in the range of from about 0.3 to about 0.6.
Claim 62
Dependent Claim
21 words
The process in accordance with claim 51 wherein the gas phase enters the reactor separate, and apart from the liquid phase.
Claim 63
Dependent Claim
18 words
The process in accordance with claim 51 wherein the liquid phase enters the reactor below the distributor plate.
Claim 64
Dependent Claim
24 words
The process in accordance with claim 51 wherein the bulk density function (Z) is greater than 1% above the calculated bulk density function limit.
Claim 65
Dependent Claim
30 words
The process in accordance with claim 51 wherein the liquid phase comprises a level of liquid greater than 20 weight percent based on the total weight of the fluidizing medium.
Claim 66
Dependent Claim
24 words
The process in accordance with claim 51 wherein the cooling capacity is controlled by adding a condensable fluid to the reactor or recycle stream.
Claim 67
Dependent Claim
26 words
The process in accordance with claim 51 wherein the bulk density function (Z) is maintained at a value greater than the calculated bulk density function limit.
Claim 68
Dependent Claim
33 words
The process in accordance with claim 51 wherein the liquid phase comprises a level of liquid greater than 22 to about 30 weight percent based on the total weight of the fluidizing medium.
Claim 69
Dependent Claim
27 words
The process in accordance with claim 1 wherein the level of liquid is greater than 22 weight percent based on the total weight of the fluidizing medium.
Claim 70
Dependent Claim
27 words
The process in accordance with claim 1 wherein the level of liquid is greater than 27 weight percent based on the total weight of the fluidizing medium.
Claim 71
Dependent Claim
29 words
The process in accordance with claim 1 wherein the level of liquid is greater than 25 to 40 weight percent based on the total weight of the fluidizing medium.
Claim 72
Dependent Claim
15 words
The process in accordance with claim 1 wherein the fluidizing medium comprises ethylene and butene-1.
Claim 73
Dependent Claim
15 words
The process in accordance with claim 1 wherein the fluidizing medium comprises ethylene and hexene-1.
Claim 74
Dependent Claim
15 words
The process in accordance with claim 1 wherein the fluidizing medium comprises ethylene and octene-1.
Claim 75
Dependent Claim
20 words
The process in accordance with claim 1 wherein the density is in the range from 0.920 g/cc to 0.939 g/cc.
Claim 76
Dependent Claim
15 words
The process in accordance with claim 16 wherein the fluidizing medium comprises ethylene and butene-1.
Claim 77
Dependent Claim
15 words
The process in accordance with claim 16 wherein the fluidizing medium comprises ethylene and hexene-1.
Claim 78
Dependent Claim
15 words
The process in accordance with claim 16 wherein the fluidizing medium comprises ethylene and octene-1.
Claim 79
Dependent Claim
32 words
The process in accordance with claim 25 wherein the level of liquid is in the range of between 30 to 50 weight percent based on the total weight of the fluidizing medium.
Claim 80
Dependent Claim
27 words
The process in accordance with claim 25 wherein the level of liquid is greater than 22 weight percent based on the total weight of the fluidizing medium.
Claim 81
Dependent Claim
27 words
The process in accordance with claim 25 wherein the level of liquid is greater than 27 weight percent based on the total weight of the fluidizing medium.
Claim 82
Dependent Claim
29 words
The process in accordance with claim 25 wherein the level of liquid is greater than 25 to 40 weight percent based on the total weight of the fluidizing medium.
Claim 83
Dependent Claim
15 words
The process in accordance with claim 35 wherein the fluidizing medium comprises ethylene and butene-1.
Claim 84
Dependent Claim
15 words
The process in accordance with claim 35 wherein the fluidizing medium comprises ethylene and hexene-1.
Claim 85
Dependent Claim
15 words
The process in accordance with claim 35 wherein the fluidizing medium comprises ethylene and octene-1.
Claim 86
Dependent Claim
22 words
The process in accordance with claim 35 wherein the rate of withdrawal of polymer product is greater than 600 lb/hr-ft 2 .
Claim 87
Dependent Claim
15 words
The process in accordance with claim 40 wherein the fluidizing medium comprises ethylene and butene-1.
Claim 88
Dependent Claim
15 words
The process in accordance with claim 40 wherein the fluidizing medium comprises ethylene and hexene-1.
Claim 89
Dependent Claim
15 words
The process in accordance with claim 40 wherein the fluidizing medium comprises ethylene and octene-1.
Claim 90
Dependent Claim
15 words
The process in accordance with claim 51 wherein the fluidizing medium comprises ethylene and butene-1.
Claim 91
Dependent Claim
15 words
The process in accordance with claim 51 wherein the fluidizing medium comprises ethylene and hexene-1.
Claim 92
Dependent Claim
15 words
The process in accordance with claim 1 wherein the fluidizing medium comprises ethylene and octene-1.
Claim 93
Dependent Claim
24 words
The process in accordance with claim 51 wherein the bulk density function (Z) is greater than 2% above the calculated bulk density function limit.
References Cited (Backward Citations)
US3639377A
Cited
EP0024933A2
Cited
EP0040992A1
Cited
US4287327A
Cited
EP0059080A2
Cited
US4442271A
Cited
EP0089691A2
Cited
US4543399A
Cited
US4588790A
Cited
EP0241947A2
Cited
US4933149A
Cited
EP0183154A2
Cited
US5028670A
Cited
WO1994014856A1
Cited
WO1994014855A1
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1998-07-24 | 1999-01-23 | 1999-07-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2002-07-24 | 2003-01-23 | 2003-07-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2006-07-24 | 2007-01-23 | 2007-07-25 | $7700.00 | Window Closed / Lapsed |