KR-102962488-B1 - Polymerization method and apparatus

KR102962488B1KR 102962488 B1KR102962488 B1KR 102962488B1KR-102962488-B1

Abstract

The present disclosure relates to a polymerization method comprising: - a step of providing a first hydrocarbon stream comprising a first olefin monomer, a first comonomer, and a solvent in a first providing step, wherein the solvent is obtained from a solvent source; - a step of combining the first hydrocarbon stream with a first combined hydrocarbon stream with a hydrocarbon recycled from at least one downstream process step in a first combining step; - a step of polymerizing the first olefin monomer and the first comonomer in a solvent in the presence of a first polymerization catalyst in a first polymerization step to produce a first solution comprising a first polymer of the first olefin monomer and the first comonomer; - a step of withdrawing a first discharge stream of the first solution in a first withdrawal step; - a step of separating the first discharge stream into a first primary hydrocarbon stream and a first concentrated solution stream in a first primary separation step; - A step of recirculating the first primary hydrocarbon stream to the first combining step in a first primary recirculation step; - A step of separating the first concentrated solution stream into a first secondary hydrocarbon stream and a first polymer product stream in a first secondary separation step; - A step of recirculating the first secondary hydrocarbon stream to the first combining step in a first secondary recirculation step; - A step of providing a second hydrocarbon stream comprising a second olefin monomer, a second comonomer, and a solvent in a second providing step, wherein the solvent is obtained from the solvent source; - A step of combining the second hydrocarbon stream with a hydrocarbon recirculated from at least one downstream process step and a second combined hydrocarbon stream in a second combining step; - A step of polymerizing the second olefin monomer and the second comonomer in the solvent in the presence of a second polymerization catalyst in a second polymerization step to produce a second solution comprising a second polymer of the second olefin monomer and the second comonomer; - A step of withdrawing a second discharge stream of the second solution in a second withdrawal step; - A step of separating the second discharge stream into a second primary hydrocarbon stream and a second concentrated solution stream in a second primary separation step; - A step of recirculating the second primary hydrocarbon stream to the second combining step in a second primary recirculation step; - A step of separating the second concentrated solution stream into a second secondary hydrocarbon stream and a second polymer product stream in a second secondary separation step; and - A step of recirculating the second secondary hydrocarbon stream to the second combining step in a second secondary recirculation step, wherein - the first providing step and the second providing step are performed in parallel; - The first combination step and the second combination step are performed in parallel; - The first polymerization step and the second polymerization step are performed in parallel; - The first withdrawal step and the second withdrawal step are performed in parallel; - The first primary separation step and the second primary separation step are performed in parallel; - The first primary recirculation step and the second primary recirculation step are performed in parallel; - The first secondary separation step and the second secondary separation step are performed in parallel; and - The first secondary recirculation step and the second secondary recirculation step are performed in parallel. The present disclosure also comprises a polymerization apparatus comprising: - a solvent source arranged to provide a solvent to a first hydrocarbon stream and a second hydrocarbon stream, wherein the first hydrocarbon stream comprises a first olefin monomer, a first comonomer, and a solvent, and the second hydrocarbon stream comprises a second olefin monomer, a second comonomer, and a solvent; - a first olefin monomer source arranged to provide a first olefin monomer to the first hydrocarbon stream; - a first comonomer source arranged to provide a first comonomer to the first hydrocarbon stream; - a first combining means fluidly connected to the solvent source, the first olefin monomer source, and the first comonomer source, wherein the first combining means arranged to combine the first hydrocarbon stream with a stream of recycled hydrocarbons and a first combined hydrocarbon stream; - A first polymerization reactor train fluidly connected to the combination means and arranged to polymerize an olefin monomer and a comonomer in the presence of a polymerization catalyst in a solvent to produce a first solution comprising a first polymer of said olefin monomer and said comonomer; - A first primary separation device fluidly connected to the first polymerization reactor train and arranged to separate a first discharge stream of said solution drawn from the first polymerization reactor train into a first primary hydrocarbon stream and a first concentrated solution stream; - A first primary recirculation means fluidly connected to the first primary separation device and the first combination means to recirculate said first primary hydrocarbon stream to the first combination means; - A first secondary separation device fluidly connected to the first primary separation device, wherein the first secondary separation device is arranged to separate said first concentrated solution stream into a first secondary hydrocarbon stream and a first polymer product stream; - A first secondary recirculation means fluidly connected to the first secondary separation device and the first combining means to recirculate the first secondary hydrocarbon stream to the first combining means; - A second combining means fluidly connected to the solvent source and arranged to combine the second hydrocarbon stream into a stream of recirculated hydrocarbons and a second combined hydrocarbon stream; - A second polymerization reactor train fluidly connected to the combining means and arranged to polymerize an olefin monomer and a comonomer in the presence of a polymerization catalyst in a solvent to produce a second solution comprising a second polymer of the olefin monomer and the comonomer; - A second primary separation device fluidly connected to the second polymerization reactor train and arranged to separate a second discharge stream of the second solution drawn from the second polymerization reactor train into a second primary hydrocarbon stream and a second concentrated solution stream; - A second primary recirculation means fluidly connected to the second primary separation device and the second combination means to recirculate the second primary hydrocarbon stream to the second combination means; - A second secondary separation device fluidly connected to the second primary separation device, wherein the second secondary separation device is arranged to separate the second concentrated solution stream into a second secondary hydrocarbon stream and a second polymer product stream; and - A second secondary recirculation means fluidly connected to the second secondary separation device and the second combination means to recirculate the second secondary hydrocarbon stream to the second combination means, wherein - the first polymerization reactor train and the second polymerization reactor train are arranged to operate in parallel; - the first primary separation device and the second separation device are arranged to operate in parallel; - the first primary recirculation means and the second primary recirculation means are arranged to operate in parallel; - The first secondary separation device and the second secondary separation device are arranged to operate in parallel; and - the first secondary recirculation means and the second secondary recirculation means are arranged to operate in parallel.

Inventors

알-하즈 알리, 무하마드
웨버, 샤를로타
슬레이스터, 헨리
아젤랄, 누레딘
사타르, 무바샤르

Assignees

보레알리스 게엠베하

Dates

Publication Date: 20260508
Application Date: 20201208

Claims (15)

A continuous polymerization method comprising the following, - A step of providing a first hydrocarbon stream comprising a first olefin monomer, a first comonomer, and a solvent in a first providing step, wherein the solvent is obtained from a solvent source; - A step of combining the first hydrocarbon stream in the first combining step with a hydrocarbon recycled from at least one downstream process step and a first combined hydrocarbon stream; - A step of continuously polymerizing the first olefin monomer and the first comonomer in a solvent in the presence of a first polymerization catalyst in a first polymerization step to produce a first solution comprising a first polymer of the first olefin monomer and the first comonomer; - A step of withdrawing a first discharge stream of the first solution in a first withdrawal step; - A step of separating the first discharge stream into a first primary hydrocarbon stream and a first concentrated solution stream in a first primary separation step; - A step of recirculating the first primary hydrocarbon stream to the first combination step in the first primary recirculation step; - A step of separating the first concentrated solution stream into a first secondary hydrocarbon stream and a first polymer product stream in a first secondary separation step; - A step of recirculating the first secondary hydrocarbon stream to the first combination step in the first secondary recirculation step; - A step of providing a second hydrocarbon stream comprising a second olefin monomer, a second comonomer, and a solvent in a second providing step, wherein the solvent is obtained from the solvent source; - A step of combining the second hydrocarbon stream in the second combining step with a hydrocarbon recycled from at least one downstream process step and a second combined hydrocarbon stream; - A step of continuously polymerizing the second olefin monomer and the second comonomer in the solvent in the presence of a second polymerization catalyst during a second polymerization step to produce a second solution comprising a second polymer of the second olefin monomer and the second comonomer; - A step of withdrawing the second discharge stream of the second solution in the second withdrawal step; - A step of separating the second discharge stream into a second primary hydrocarbon stream and a second concentrated solution stream in a second primary separation step; - A step of recirculating the second primary hydrocarbon stream to the second combination stage in the second primary recirculation stage; - A step of separating the second concentrated solution stream into a second secondary hydrocarbon stream and a second polymer product stream in a second secondary separation step; and - A step of recirculating the second secondary hydrocarbon stream to the second combination stage in the second secondary recirculation stage, Here, - The first providing step and the second providing step are performed in parallel; - The above first combination step and the above second combination step are performed in parallel; - The first polymerization step and the second polymerization step are performed in parallel; - The above first withdrawal step and the above second withdrawal step are performed in parallel; - The above first separation step and the above second separation step are performed in parallel; - The above-mentioned first primary recirculation step and the above-mentioned second primary recirculation step are performed in parallel; - The above first secondary separation step and the above second secondary separation step are performed in parallel; and - A continuous polymerization method in which the first secondary recirculation step and the second secondary recirculation step are performed in parallel.
In claim 1, the second olefin monomer is in the same continuous polymerization method as the first olefin monomer.
A continuous polymerization method according to claim 1 or 2, wherein the second comonomer is the same as the first comonomer.
A continuous polymerization method according to claim 1 or 2, comprising the steps of combining the first secondary hydrocarbon stream and the second secondary hydrocarbon stream into a third combined hydrocarbon stream and recirculating the third combined hydrocarbon stream to the first combining step and/or the second combining step.
In paragraph 4, The above third combined hydrocarbon stream is separated into a light hydrocarbon stream and a heavy hydrocarbon stream in a third separation stage; The light hydrocarbon stream is recirculated to the first combination step and/or the second combination step; and A continuous polymerization method in which the above heavy hydrocarbon stream is recirculated to the above first combination step and/or the above second combination step.
A polymerization apparatus comprising the following, - A solvent source configured to provide a solvent to a first hydrocarbon stream and a second hydrocarbon stream, wherein the first hydrocarbon stream comprises a first olefin monomer, a first comonomer, and a solvent, and the second hydrocarbon stream comprises a second olefin monomer, a second comonomer, and a solvent; - A first olefin monomer source arranged to provide a first olefin monomer to the first hydrocarbon stream; - A first comonomer source arranged to provide a first comonomer to the first hydrocarbon stream; - A first combining means fluidly connected to the solvent source, the first olefin monomer source, and the first comonomer source, wherein the first combining means is arranged to combine the first hydrocarbon stream into a stream of recycled hydrocarbon and a first combined hydrocarbon stream; - A first polymerization reactor train fluidly connected to the above combination means and arranged to continuously polymerize an olefin monomer and a comonomer in the presence of a polymerization catalyst in a solvent to produce a first solution comprising a first polymer of the olefin monomer and the comonomer; - A first primary separation device fluidly connected to the first polymerization reactor train and arranged to separate a first discharge stream of the first solution drawn from the first polymerization reactor train into a first primary hydrocarbon stream and a first concentrated solution stream; - A first primary recirculation means fluidly connected to the first primary separation device and the first combination means to recirculate the first primary hydrocarbon stream to the first combination means; - A first secondary separation device fluidly connected to the first primary separation device, wherein the first secondary separation device is configured to separate the first concentrated solution stream into a first secondary hydrocarbon stream and a first polymer product stream; - A first secondary recirculation means fluidly connected to the first secondary separation device and the first combination means to recirculate the first secondary hydrocarbon stream to the first combination means; - A second combining means fluidly connected to the solvent source and arranged to combine the second hydrocarbon stream with a stream of recycled hydrocarbons and a second combined hydrocarbon stream; - A second polymerization reactor train fluidly connected to the above combination means and arranged to continuously polymerize an olefin monomer and a comonomer in the presence of a polymerization catalyst in a solvent to produce a second solution comprising a second polymer of the olefin monomer and the comonomer; - A second primary separation device fluidly connected to the second polymerization reactor train and arranged to separate the second discharge stream of the second solution drawn from the second polymerization reactor train into a second primary hydrocarbon stream and a second concentrated solution stream; - A second primary recirculation means fluidly connected to the second primary separation device and the second combination means to recirculate the second primary hydrocarbon stream to the second combination means; - A second secondary separation device fluidly connected to the second primary separation device, wherein the second secondary separation device is configured to separate the second concentrated solution stream into a second secondary hydrocarbon stream and a second polymer product stream; and - A second secondary recirculation means fluidly connected to the second secondary separation device and the second secondary combination means to recirculate the second secondary hydrocarbon stream to the second combination means. Here, - The first polymerization reactor train and the second polymerization reactor train are arranged to operate in parallel; - The first primary separation device and the second primary separation device are arranged to operate in parallel; - The above-mentioned first primary recirculation means and the above-mentioned second primary recirculation means are arranged to operate in parallel; - The first secondary separation device and the second secondary separation device are arranged to operate in parallel; and - A polymerization device in which the first secondary recirculation means and the second secondary recirculation means are arranged to operate in parallel.
In paragraph 6, The first olefin monomer source is fluidly connected to the second combining means; and A polymerization apparatus in which the first olefin monomer source is arranged to provide a second olefin monomer to the second hydrocarbon stream.
In paragraph 6 or 7, The polymerization apparatus comprises a second olefin monomer source arranged to provide a second olefin monomer to the second hydrocarbon stream; and The above second olefin monomer source is a polymerization device fluidly connected to the above second combining means.
In paragraph 6 or 7, The above-mentioned first comonomer source is fluidly connected to the above-mentioned second combining means; and The above-mentioned first comonomer source is a polymerization apparatus arranged to provide a second comonomer to the above-mentioned second hydrocarbon stream.
In paragraph 6 or 7, The polymerization apparatus comprises a second comonomer source arranged to provide a second comonomer to the second hydrocarbon stream; and The above second comonomer source is a polymerization device fluidly connected to the above second combination means.
In paragraph 6 or 7, a) between the first olefin monomer source and the second combination means, or b) between the second olefin monomer source and the second combining means A polymerization device comprising a first valve means for selectively opening a passage.
In paragraph 6 or 7, a) between the first comonomer source and the second combination means, or b) between the second comonomer source and the second combining means A polymerization device comprising a second valve means for selectively opening a passage.
In paragraph 6 or 7, The first secondary separation device is fluidly connected to the second combination means; and The polymerization device comprises a third valve means for selectively opening a passage from the first secondary separation device to the first combination means and/or the second combination means.
In paragraph 6 or 7, The second secondary separation device is fluidly connected to the first combination means; and The polymerization device comprises a fourth valve means for selectively opening a passage from the second secondary separation device to the first combination means and/or the second combination means.
In paragraph 6 or 7, The above-mentioned first secondary recirculation means and the above-mentioned second secondary recirculation means are - A third separation device fluidly connected to the first secondary separation device and the second secondary separation device and arranged to separate a third combined hydrocarbon stream into a light hydrocarbon stream and a heavy hydrocarbon stream, wherein the third combined hydrocarbon stream is a combination of the first secondary hydrocarbon stream and the second secondary hydrocarbon stream; - Light hydrocarbon recirculation means fluidly connected to the third separation device, the first combination means, and the second combination means, and arranged to recirculate the light hydrocarbon stream to the first combination means and/or the second combination means; and - Heavy hydrocarbon recirculation means fluidly connected to the above-mentioned third separation device, the above-mentioned first combining means, and the above-mentioned second combining means, and arranged to recirculate the heavy hydrocarbon stream to the above-mentioned first combining means and/or the above-mentioned second combining means. A polymerization apparatus including

Description

Polymerization method and apparatus The present disclosure relates to a polymerization method, and in particular to a solution polymerization method. The present disclosure relates to a corresponding polymerization arrangement. Reference WO 2017/108951 A1 describes the step of (a) providing two or more reactor-low pressure separator units in a parallel configuration, wherein each reactor-low pressure separator unit comprises an additional recirculation line in which one reactor and low pressure separator are fluidly connected downstream to one low pressure separator and the low pressure separator are reconnected to the corresponding reactor; (b) polymerizing an olefin monomer having two or more carbon atoms in each reactor in a solution polymerization; (c) forming an unreduced reactor effluent stream comprising a homogeneous fluid phase polymer-monomer-solvent mixture in each reactor; (d) passing the unreduced reactor effluent stream from each reactor through a corresponding low-pressure separator, adjusting the temperature and pressure of the low-pressure separator so as to obtain a liquid phase and a gas phase, thereby producing a polymer-rich liquid phase and a polymer-lean gas phase; and (e) separating the polymer-lean gas phase from the polymer-rich liquid phase in each low-pressure separator to form a separated polymer-lean vapor stream and a separated polymer-rich liquid stream; (f) combining the polymer-rich liquid stream from step (e) in an additional low-pressure separator and/or mixer to produce a combined polymer-rich liquid stream; and (g) reintroducing the polymer-lean vapor stream from step (e) into the corresponding reactor through a recirculation line, thereby initiating an in-line blending process for a polymer. Document WO 2017/108969 A1 discloses a process for polymerizing an olefin in solution and withdrawing a stream of solution from a polymerization reactor and passing it through a series of heating stages. The heated solution is transferred to a separation stage in which a liquid phase and a gas phase containing a polymer coexist, which is carried out at a pressure of 15 bar or less. A vapor stream and a concentrated solution stream containing a polymer are withdrawn from the separation stage. At least a portion of the vapor stream passes through a first polymerization reactor, a second polymerization reactor, or both. The problem with the two aforementioned processes is that they cannot produce two different types of polyethylene simultaneously, but the product streams are combined and the combined product is sent to extrusion. Document WO 2019/086987 A1 discloses an integrated solution polymerization method comprising the following. i. A step of compressing ethylene in a single compressor to form a compound ethylene stream; ii. A step of dividing the compressed ethylene stream into a first ethylene supply stream and a second ethylene supply stream; iii. Injecting the first ethylene feed stream, hydrocarbon solvent, first catalyst system, optionally one or more C3 to C12 alpha olefins, and optionally hydrogen into a first polymerization reaction train operating at a first temperature and a first pressure to produce a first ethylene polymer solution; iv. injecting the second ethylene feed stream, hydrocarbon solvent, second catalyst system, one or more C3 to C12 alpha olefins, and optionally hydrogen into a second polymerization reaction train operating at a second temperature and a second pressure to produce a second ethylene polymer solution; v. sending the first ethylene polymer solution to a first polymer separation unit operation to produce a first liquid stream containing the first solvent, unreacted monomers, and crude first ethylene polymer; v. sending the second ethylene polymer solution to a second polymer separation unit operation to produce a second liquid stream containing the second solvent, unreacted monomer, and crude second ethylene polymer; vi. sending the first liquid stream and the second liquid stream to a single distillation unit; vii. A step of finishing the first ethylene polymer of the above-mentioned crude state in a finishing operation including a pellet extruder and a pellet stripper; and viii. A step of finishing the second ethylene copolymer of the above-mentioned crude state in a second finishing operation comprising a devolatilizing extruder, wherein the second finishing extruder does not include a pellet stripper. The problem with the above method is that it does not include short recirculation, that is, recirculating the separated hydrocarbons back upstream of the polymerization train immediately after the polymerization reaction train. This consumes energy and requires relatively large equipment to distill the hydrocarbons in subsequent process steps. The present disclosure will be described in detail below by preferred embodiments with reference to the accompanying drawings. FIG. 1a is a schematic diagram of a polymerization method according to one