Patente US7582708 - Bulk polymerization reactor methods

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BULK POLYMERIZATION REACTOR
METHODS

RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/297,931, filed Jun. 13, 2001.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to reactors for conducting polymerization of monomers, and in particular, bulk polymerization reactors for conducting polymerization of alpha-olefin monomers. 15

2. Description of Related Art

Formation of polymers from various monomers is a wellknown art. As is also well known in the art, the polymerization reactor in which the polymers are formed from the monomers have certain inherent limitations to efficiently form the poly- 20 mers. A major inherent limitation is the removal of heat from the polymerization reactor created by the chemical reaction between the monomers and the catalyst during formation of the polymers. To overcome this problem, cooling systems have been designed to encase the polymerization reactor in an 25 attempt to remove the heat from the polymerization reactor. Additionally, cooling additives may be included in the polymerization reaction mixture in the polymerization reactor.

Both of these prior attempts, however, have various shortcomings. For example, the use of cooling systems outside the 30 polymerization reactor do not efficiently and effectively remove heat from the polymerization reactor, especially for the center most region of the polymerization reactor. Accordingly, the size of the polymerization reactor must be small and limited amounts of polymer may be formed in each reactor 35 batch. Additionally, with respect to the addition of cooling additives to the polymerization reactants, these cooling additives can have an adverse effect on the quality of the polymer as well as increasing the cost associated with forming the polymer. 40

In other prior attempts, as discussed in U.S. Pat. Nos. 5,449,732, entitled Solvent Free Oil Soluble Drag Reducing Polymer Suspension, 5,504,131, entitled Solvent Free Oil Soluble Drag Reducing Polymer Suspension, and 5,504,132, entitled Solvent Free Oil Soluble Drag Reducing Polymer 45 Suspension, the polymerization reactor is a crystalline, hydrocarbon-insoluble organic polymer reaction enclosure capable of substantially preventing passage of oxygen and water, i.e., plastic bags. Use of these plastic bags permits the polymerization reaction to be carried out without a cooling 50 system or addition of cooling additives. However, because the plastic bags are not provided with any assistance in the removal of heat from the polymerization reaction, only small amounts of polymer reactants, e.g., monomer and catalyst, can be included in each plastic bag. As such, only small 55 amounts of polymer can be formed in each of this type of polymerization reactor. Further, the plastic bags can not be easily separated from the polymer, and thus, are not re-useable.

Accordingly, prior to the development of the present inven- 60 tion, there has been no polymerization reactor or process for forming polymers, which: effectively remove heat away from the polymerization reactor; permit the formation of a large amount of polymer in each polymerization reactor; do not require the addition of cooling additives; and permit the use of 65 a re-useable polymerization reactor. Therefore, the art has sought a polymerization reactor and a process for forming

polymers, which: effectively remove heat away from the polymerization reactor; permit the formation of a large amount of polymer in each polymerization reactor; do not require the addition of cooling additives; and permit the use of a re-useable polymerization reactor.

SUMMARY OF INVENTION

In accordance with the invention, the foregoing advantages have been achieved through the present polymerization method for polymerization of olefins comprising: adapting a reservoir having at least three side wall surfaces and a bottom wall surface thereby forming a reservoir cavity; adapting at least one heat exchanger plate in fluid communication with a coolant source; and adapting a lid having a top wall surface and an inner wall surface, wherein the at least one heat exchanger plate is disposed along inner wall surface.

A further feature of the polymerization reactor is that the polymerization reactor may comprise four side wall surfaces. Another feature of the polymerization reactor is that each of the four side wall surfaces may have a square shape having a length and a height. An additional feature of the polymerization reactor is that two of the four side wall surfaces may have a length of at least two feet and a height of at least two feet and the other two of the four side wall surfaces may have a length of at least three feet and a height of at least two feet. Still another feature of the polymerization reactor is that the lid may be rectangularly shaped having a length and a width, the length being at least three feet and the width being at least two feet. A further feature of the polymerization reactor is that the lid may include at least two heat exchanger plates. Another feature of the polymerization reactor is that each of the at least two heat exchanger plates may be disposed at a distance of at least three inches from each other. An additional feature of the polymerization reactor is that the polymerization reactor may further comprise at least one coolant inlet manifold in fluid communication with the coolant source and at least one coolant outlet manifold in fluid communication with the coolant source. Still another feature of the polymerization reactor is that the polymerization reactor may further comprise at least one coolant inlet conduit in fluid communication with the at least one coolant inlet manifold and in fluid communication with each of the at least one heat exchanger plates, and at least one coolant outlet conduit in fluid communication with the at least one coolant outlet manifold and in fluid communication with each of the at least one heat exchanger plates. A further feature of the polymerization reactor is that the lid may include a plate hanger assembly disposed along the inner wall surface for attaching each of the at least one heat exchanger plates to the inner wall surface of the lid. Another feature of the polymerization reactor is that each of the at least one heat exchanger plates may be in fluid communication with a coolant inlet conduit and a coolant outlet conduit. An additional feature of the polymerization reactor is that each of the coolant inlet conduits may be in fluid communication with a coolant inlet manifold and each of the coolant outlet conduits may be in fluid communication with a coolant outlet manifold. Still another feature of the polymerization reactor is that the coolant inlet manifold and the coolant outlet manifold may be in fluid communication with the coolant source. A further feature of the polymerization reactor is that the reservoir may include four walls having a length, the length being at least 4 feet, and a width, the width being at least 2 feet. Another feature of the polymerization reactor is that the inner wall surface of the lid may include at least 6 heat exchanger

3 4

plates. An additional feature of the polymerization reactor is and equivalents, as may be included within the spirit and

that each of the at least one heat exchanger plate may include scope of the invention as defined by the appended claims, a removable film.

T , • .. f A . DETAILED DESCRIPTION OF THE INVENTION In accordance with the invention, the foregoing advantages

have also been achieved through the present polymerization 5 _ ^, , . ^. „^

n . .. Pt^ . . . Broadly, the polymerization reactor of the present mven

reactor lor polymerization of olefins comprising: a reservoir .. . , , . , , . , , ,

. , • P ii tion includes a reservoir and a lid having a heat exchanger,

having at least three side wall surfaces and a bottom wall ^ ud ig ... Qn ^ ... the head exchanger is

surface thereby forming a reservoir cavity; a heat exchanger, disposed within the reservoir thereby cooling, i.e., removing

the heatexchangerhavingaheatexchangerassembly, coolant 1Q heat from, the contents of the reservoir.

inlet manifold in fluid communication with a coolant source, Referring now to FIGS. 1 -3, in one specific embodiment of

at least one coolant inlet conduit in fluid communication with the present invention, polymerization reactor 40 includes res

at least one heat exchanger plate, at least one coolant outlet ervoir 80 and lid 70. Lid 70 includes heat exchanger 60.

conduit in fluid communication with each of the at least one Reservoir 80 includes at least three wall surfaces and a bottom

heat exchanger plate and in fluid communication with a cool- 15 wall surface to form a cavity. As shown in FIGS. 1 -3, reservoir

ant outlet manifold, the coolant outlet manifold in fluid com- preferably includes four side wall surfaces, 81,82,83,84, and

munication with the coolant source; and a lid having a top bottom wall surface 85 to form reservoir cavity 87. While it is

wall surface and an inner wall surface, wherein the at least one to be understood that additional wall surfaces may be

heat exchanger plate is disposed along inner wall surface. included as part of reservoir 80, thereby permitting reservoir

A further feature of the polymerization reactor is that the 20 ?°to ha^e TM\ desir,ed ^ Preferably reservoir 80 includes

, ... , j- j- four wall surfaces thereby having a rectangular shape (FIGS,

polymerization reactor comprises lour side wall surfaces, two ^ bhd

of the four side wall surfaces having a length of at least two 2' . „„ " „' , , . , , . , . , ., oc) 4

. , , • , r , r 1 1 r 1 r Reservoir 80 preferably includes at least one skid 88. As

ieet and a height oi at least two ieet, the other two oi the lour , . ^T^0 \ , « • OA • , , , •, 00

,r , . shown in FIGS. 1 and 3, reservoir 80 includes two skids 88.

side wall surfaces having a length of at least three feet and a ^ skids 88 ^ a ... Qr Qther lifting tQ engage

height of at least two feet, and the lid is rectangularly shaped reservoir 80 so that it can be moved to any desired location,

havingalengthandawidth,thelengthbeingatleastthreefeet j e^ to be placed near sources of monomer that are t0 be

and the width being at least two feet. charged, or transported, into reservoir 80.

In accordance with the invention, the foregoing advantages As shown in FIGS. 1 and 3, reservoir 80 includes length 92, have also been achieved through the present method of poly- 30 height 91, and width 93. Length 92, height 91, and width 93 merization comprising the steps of: combining at least one may be any distance as desired by the person using polymermonomer and at least one catalyst in a reservoir to form a ization reactor 40. It is to be understood, however, that genpolymerization reaction mixture, the reservoir having at least erally, as length 92 increases, the number of heat exchanger three side walls and a bottom wall thereby forming a reservoir Plates 66 also increases, and as height 91 and width 93 cavity; inserting at least one heat exchanger plate having an 35 increase, the dimensions of heat exchanger plate 66 increases, exchanger cavity in fluid communication with a coolant In one sPeclfic embodiment, length 92, height 91, and width

• . „ • 1 1 93 are equal and each are at least 2 feet. In this embodiment,

source into the reservoir cavity thereby contacting the poly-" .'

• ,. ,. • , , , , polymerization reactor 40 is cubed shaped. In a preferred

menzation reaction mixture; and removing the at least one , ,. , , „„. , ~n

, ^ , , ^ „ ^ ^. . ° „ m . , embodiment, length 92 is at least 3 Ieet, height 91 is at least 2

heat exchanger plate from the reaction mixture alter sufficient „ ^ , .,',„«. ^, ^ „ p ^ T J • r- 1 1 v

, , . . . n , , 40 feet, and width 93 is at least 2 feet. In this preferred embodi

time has passed to permit a maionty of the at least one mono- , ... , .„. , , , ,

r r ■> J ment, polymerization reactor 40 is rectangularly shaped.

mer to form a polymer. Reservoir 80 may be formed out of any material known to

A further feature of the method of polymerization is that persons of ordinary skill in the art. Preferably, reservoir 80 is

the method may further comprise the step of disposing a formed out of stainless steel.

removable film on each of the at least one heat exchanger 45 Referring now to FIGS. 1-3, lid 70 includes top wall sur

plate prior to inserting the at least one heat exchanger plate face 73 and side wall surfaces 72, 74, 75, 76. Lip 71 may be

into the reservoir cavity. included to provide additional strength. Lid 70 provides pro

The polymerization reactor and process for forming poly- tection to heat exchanger 60 from the environment and pre

mers have the advantages of: effectively removing heat away vents items from falling onto heat exchanger 60 and into

from the polymerization reactor; permitting the formation of 50 reservoir 80. Lid 70 also includes an inner surface 77 to which

a large amount of polymer in each polymerization reactor; not heat exchanger 60 is attached. Lid 70 may be formed out of

requiring the addition of cooling additives; and permitting the any material known to persons of ordinary skill in the art.

use of a re-useable polymerization reactor. Preferably, lid 70 is formed out of stainless steel.

Heat exchanger 60 preferably includes plate hanger assem

BRIEF DESCRIPTION OF DRAWINGS 55 bly 61, coolant inlet manifold 62, coolant outlet manifold 63,

at least one coolant inlet conduit 64, at least one coolant outlet

A ■ -j • j- -r- , j- . p.i conduit 65, and at least one heat exchanger plate 66 having

FIG. 1 is a side view of one specific embodiment of the . . „ TT . . ,.° f. ... , ,°

, ... P., ,. ,. exchanger cavity 69. Hanger assembly 61 preferably includes

polymerization reactor of the present invention. , , °_„ J . f p ,, ,

bracket 59 to permit attachment of each heat exchanger 66 to

FIG. 2 is a perspective view of the heat exchanger of the g0 jjd

polymerization reactor shown in FIG. 1. Coolant inlet manifold 62 is in fluid communication with at

FIG. 3 is a perspective view of the polymerization reactor ieast 0ne coolant inlet conduit 64 which is in fluid communi

shown in FIG. 1. cation with heat exchanger plate 66. Likewise, coolant outlet

While the invention will be described in connection with manifold 63 is in fluid communication with at least one cool

the preferred embodiment, it will be understood that it is not 65 ant outlet conduit 65 which is in fluid communication with

intended to limit the invention to that embodiment. On the heat exchanger plate 66. In one specific embodiment, having

contrary, it is intended to coverall alternatives, modifications, one heat exchanger plate 66, one of each of coolant inlet

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Bulk polymerization reactor methods