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BR-112024004962-B1 - METHOD COMPRISING A CATALYST SYSTEM COMPONENT

BR112024004962B1BR 112024004962 B1BR112024004962 B1BR 112024004962B1BR-112024004962-B1

Abstract

HYDROCYCLONE MODIFICATION OF CATALYST SYSTEM COMPONENTS FOR USE IN OLEFIN POLYMERIZATIONS. Methods are disclosed for modifying a catalyst system component in which a feed mixture containing a fluid and 1 to 15 wt% of a catalyst system component is introduced into the inlet of a hydrocyclone, an overflow stream containing 0.1 to 5 wt% solids and an underflow stream containing 10 to 40 wt% solids are discharged from the hydrocyclone, and the underflow stream is spray-dried to form a modified catalyst component. Frequently, 4 to 20 wt% of the catalyst system component in the feed mixture has a particle size less than or equal to 20 μm, or less than or equal to 10 μm.

Inventors

  • CARLOS A. CRUZ
  • MITCHELL D. REFVIK
  • MAX P. MCDANIEL
  • Mark Scott
  • Evan Merk

Assignees

  • CHEVRON PHILLIPS CHEMICAL COMPANY LP
  • THE SHEPHERD CHEMICAL COMPANY

Dates

Publication Date
20260310
Application Date
20220912
Priority Date
20210913

Claims (20)

  1. 1. A method characterized in that it comprises: (I) introducing a feed mixture containing a liquid and 1 to 15% by weight of a catalyst system component having a wet particle density of 1.05 to 2.0 g/cm3 into the inlet of a hydrocyclone at a linear velocity of 2 to 20 ft/s (0.6 to 6.1 m/s), wherein 4 to 20% by weight of the catalyst system component has a particle size less than or equal to 20 μm; and (II) discharging from the hydrocyclone an overflow stream containing 0.1 to 5% by weight of solids and an underflow stream containing 10 to 40% by weight of solids.
  2. 2. Method according to claim 1, characterized in that it further comprises a spray-drying step of the underflow stream to form a modified catalyst component.
  3. 3. Method according to claim 1, characterized in that it further comprises the steps of: a) determining a particle size characteristic of the catalyst system component in the feed mixture, and b) adjusting a hydrocyclone processing parameter based on the particle size feature; and/or A) determining a particle size characteristic of the catalyst system component in the downstream stream, and B) adjusting a hydrocyclone processing parameter based on the particle size characteristic.
  4. 4. Method according to claim 1, characterized in that it further comprises the steps of: (III) introducing the overflow stream into a second inlet of a second hydrocyclone; (IV) discharging from the second hydrocyclone a second overflow stream containing 0.05 to 2.5 wt% solids and a second underflow stream containing 0.5 to 15 wt% solids; and (V) spray-drying the first underflow stream and/or the second underflow stream to form a modified catalyst component.
  5. 5. Method according to claim 1, characterized in that it further comprises the steps of: (III) introducing the underflow stream into a second inlet of a second hydrocyclone; (IV) discharging from the second hydrocyclone a second overflow stream containing 0.1 to 15 wt% solids and a second underflow stream containing 10 to 40 wt% solids; and (V) spray-drying the second overflow stream to form a modified catalyst component.
  6. 6. Method according to claim 1, characterized in that the liquid comprises water.
  7. 7. Method according to claim 1, characterized in that the feed mixture contains the liquid and 4 to 10% by weight of the catalyst system component.
  8. 8. Method according to claim 1, characterized in that: the catalyst system component in the feed mixture has a d50/d5 ratio in a range of 4 to 8 and a d95/d5 ratio in a range of 8 to 20; and the catalyst system component in the downstream stream has a d50/d5 ratio in a range of 1.5 to 3.6 and a d95/d5 ratio in a range of 3 to 7.5.
  9. 9. Method according to claim 1, characterized in that: the catalyst system component in the feed mixture has a d50/d5 ratio in a range of 4 to 6.5 and a d95/d5 ratio in a range of 8 to 16; and the catalyst system component in the downstream stream has a d50/d5 ratio in a range of 2 to 3.5 and a d95/d5 ratio in a range of 4 to 7.
  10. 10. Method according to claim 1, characterized in that: an amount of the catalyst system component having a particle size less than or equal to 10 μm in the feed mixture is in a range of 5 to 16 % by weight; and an amount of the catalyst system component having a particle size less than or equal to 10 μm in the overflow stream is in a range of 35 to 90 % by weight.
  11. 11. Method according to claim 10, characterized in that an amount of the catalyst system component having a particle size less than or equal to 10 μm in the underflow stream is less than or equal to 4% by weight.
  12. 12. Method according to claim 1, characterized in that: an amount of the catalyst system component having a particle size less than or equal to 10 μm in the feed mixture is in a range of 7 to 15 % by weight; and an amount of the catalyst system component having a particle size less than or equal to 10 μm in the downstream stream is less than or equal to 3 % by weight.
  13. 13. Method according to claim 12, characterized in that the catalyst system component in the overflow stream has an average particle size d50 in a range of 3 to 12 μm.
  14. 14. Method according to claim 13, characterized in that: the density of wet particles is in a range of 1.2 to 1.8 g/cm3; and the catalyst system component in the feed mixture has a BET surface area in a range of 50 to 1000 m2/g and an average particle size d50 in a range of 25 to 60 μm.
  15. 15. A method characterized in that it comprises: (i) introducing a feed mixture containing a liquid and 1 to 15% by weight of a catalyst system component into the inlet of a hydrocyclone, wherein 4 to 20% by weight of the catalyst system component has a particle size less than or equal to 20 μm; (ii) discharging from the hydrocyclone an overflow stream containing 0.1 to 5% by weight of solids and an underflow stream containing 10 to 40% by weight of solids; and (iii) spray-drying the underflow stream to form a modified catalyst component.
  16. 16. Method according to claim 15, characterized in that: the liquid comprises water; and the catalyst system component has a wet particle density of 1.2 to 1.8 g/cm3.
  17. 17. Method according to claim 15, characterized in that the catalyst system component comprises a solid oxide, a chemically treated solid oxide, a zeolite, or a combination thereof.
  18. 18. Method according to claim 15, characterized in that the feed mixture contains the liquid and 4 to 10% by weight of the catalyst system component.
  19. 19. Method according to claim 15, characterized in that: an amount of the catalyst system component having a particle size less than or equal to 10 μm in the feed mixture is in a range of 5 to 16 % by weight; and an amount of the catalyst system component having a particle size less than or equal to 10 μm in the overflow stream is in a range of 35 to 90 % by weight.
  20. 20. Method according to claim 19, characterized in that an amount of the catalyst system component having a particle size less than or equal to 10 μm in the underflow stream is less than or equal to 4% by weight.

Description

REFERENCE TO RELATED REQUEST [001] This application is being filed on September 12, 2022, as a PCT International Patent Application and claims priority to U.S. Provisional Patent Application No. 63/243,228, filed on September 13, 2021, the disclosure of which is incorporated herein by reference in its entirety. FIELD OF THE INVENTION [002] This disclosure relates generally to methods for modifying the particle size distribution of catalyst system components using one or more hydrocyclones. FUNDAMENTALS OF THE INVENTION [003] Inappropriate particle size characteristics of catalyst system components used in catalyst compositions – such as metallocene, Ziegler-Natta, and chromium catalyst compositions – can lead to operational difficulties during olefin-based polymerizations in cyclic fluidized slurry reactors and fluidized bed reactors, as well as inconsistent properties of the resulting olefin polymer. It would be beneficial to develop methods to modify the catalyst system components that overcome these disadvantages. Consequently, it is to these purposes that the present invention is generally directed. SUMMARY OF THE INVENTION [004] This summary is provided to present a selection of concepts that are better described below in the detailed description. This summary is not intended to identify necessary or essential features of the claimed subject matter. Nor is it intended to be used to limit the scope of the claimed subject matter. [005] A first method consistent with an aspect of this invention may comprise (i) introducing a feed mixture containing a fluid and 1 to 15 wt% of a catalyst system component into an inlet of a hydrocyclone, wherein 4 to 20 wt% of the catalyst system component has a particle size less than or equal to 20 μm, (ii) discharging from the hydrocyclone an overflow stream containing 0.1 to 5 wt% solids and an underflow stream containing 10 to 40 wt% solids, and (iii) spray-drying the underflow stream to form a modified catalyst component. [006] In another aspect of this invention, a second method may comprise (I) introducing a feed mixture containing a fluid and 1 to 15 % by weight of a catalyst system component having a wet particle density of 1.05 to 2.0 g/cm3 into an inlet of a hydrocyclone at a linear velocity of 2 to 20 ft/s (0.6 to 6.1 m/s), wherein 4 to 20 % by weight of the catalyst system component has a particle size less than or equal to 20 μm, and (II) discharging from the hydrocyclone an overflow stream containing 0.1 to 5 % by weight of solids and an underflow stream containing 10 to 40 % by weight of solids. [007] A third method according to yet another aspect of this invention may comprise (a) introducing a feed mixture containing a fluid and 1 to 15 wt% of a catalyst system component into a first inlet of a first hydrocyclone, wherein 4 to 20 wt% of the catalyst system component has a particle size less than or equal to 20 μm, (b) discharging from the first hydrocyclone a first overflow stream containing 0.1 to 5 wt% solids and a first underflow stream containing 10 to 40 wt% solids, (c) introducing the first overflow stream into a second inlet of a second hydrocyclone, and (d) discharging from the second hydrocyclone a second overflow stream containing 0.05 to 2.5 wt% solids and a second underflow stream containing 0.5 to 15 wt% solids. [008] In yet another aspect consistent with this invention, a fourth method may comprise (a) introducing a feed mixture containing a fluid and 1 to 15 wt% of a catalyst system component into a first inlet of a first hydrocyclone, wherein 4 to 20 wt% of the catalyst system component has a particle size less than or equal to 20 μm, (b) discharging from the first hydrocyclone a first overflow stream containing 0.1 to 5 wt% solids and a first underflow stream containing 10 to 40 wt% solids, (c) introducing the first underflow stream into a second inlet of a second hydrocyclone, and (d) discharging from the second hydrocyclone a second overflow stream containing 0.1 to 15 wt% solids and a second underflow stream containing 10 to 40 wt% solids. [009] Modified catalyst components are also provided herein and, in some respects, such compositions may have or be characterized by i) a wet particle density in the range of 1.05 to 2.0 g/cm3, ii) a BET surface area in the range of 50 to 1000 m2/g, iii) an average particle size d50 in the range of 20 to 200 μm, iv) a d50/d5 ratio in the range of 1.5 to 3.6, and v) a d95/d5 ratio in the range of 3 to 7.5, wherein less than or equal to 4 % by weight of the modified catalyst component have a particle size less than or equal to 20 μm. [010] Furthermore, systems for modifying a catalyst system component are also disclosed herein, and a representative system may comprise (a) a hydrocyclone configured to separate a feed mixture containing a fluid and 1 to 15 % by weight of the catalyst system component, wherein a first quantity of the catalyst system component in the feed mixture has a particle size less th