Title of Invention

OLEFIN POLYMERIZATION PROCESS WITH SEQUENTIAL DISCHARGING

Abstract The present invention relates to a polymerization process for producing olefin polymers in a loop reactor comprising two or more settling legs, comprising the steps of: - introducing into the loop reactor one or more olefin reactants, polymerization catalysts and diluents, and while circulating said reactants, catalysts and diluents; - polymerizing said one or more olefin reactants to produce a polymer slurry comprising essentially liquid diluent and solid olefin polymer particles; said process further comprising one or more cycles of: (a) allowing said polymer slurry to settle into said settling legs, and (b) sequentially discharging said settled polymer slurry from said two or more settling legs out of the reactor, whereby the aggregate time of discharge of all the legs is more than 50%, preferentially more than 80% and most preferably more than 95% of the time interval between two triggerings of the same setding leg.
Full Text Field of the invention
The present invention relates to improvements in the removal of polymer slurry from a
reactor for olefin slurry polymerization. More in particular the present invention relates to
olefin polymerization process wherein the produced polymer is sequentially discharged
through sequentially operated settling legs.
Background of the invention
Olefin polymerizations such as ethylene polymerization are frequently carried out using
monomer, diluent and catalyst and optionally co-monomers in a loop reactor. The
polymerization is usually performed under slurry conditions, wherein the product consists
usually of solid particles and is in suspension in a diluent. The slurry contents of the
reactor are circulated continuously with a pump to maintain efficient suspension of the
polymer solid particles in the liquid diluent, the product being often taken off by means of
settling legs which operate on a batch principle to recover the product. Settling in the legs
is used to increase the solids concentration of the slurry finally recovered as product
slurry. The product is further either transferred to another reactor or discharged to a flash
tank, through flash lines, where most of the diluent and unreacted monomers are flashed
off and recycled. The polymer particles are dried, additives can be added and finally the
polymer is extruded and pelletized. This technique has enjoyed international success with
millions of tons of ethylene polymers being so produced annually.
In these polymerization processes, settling legs, however, do present some problems.
They represent the imposition of a "batch" or "discontinuous" technique onto a basic
continuous process. Each time a settling leg reaches the stage where it "discharges" or
"fires" accumulated polymer slurry it causes interferences on the pressure in the loop
reactor, which is thereby not kept constant. Pressure fluctuations in the loop reactor may
be larger than 1 bar. At very high monomer concentration, such pressure fluctuations may
generate several problems such as the creation of gas bubbles that may cause trouble in
the operation of the circulation pump. They may also provoke perturbations in the control
scheme of the reactor pressure.
Various alternative product removal techniques are however known. For example, WO
01/05842 describes an apparatus for removing concentrated slurry from a flowing stream

of slurry in a conduit characterized by a channel in an outlet area of the conduit, the outlet
being adapted to continuously remove slurry.
EP 0891990 describes an olefin polymerization process wherein the product slurry is
recovered by means of a continuous product take off, more in particular by means of an
elongated hollow appendage provided on the reactor. Said hollow appendage being in
direct fluid communication with a heated flash line and thus being adapted for continuous
removal of product slurry.
However the above-described apparatus and processes have the disadvantage that the
suspension withdrawn from the reactor still contains a large amount of diluent and of other
reactants, such as the monomer, which it is then necessary to subsequently separate
from the polymer particles and to treat for the purpose of reusing it in the reactor. Another
disadvantage of the above-described apparatus and processes is their lack of flexibility
during the phase or reaction start-up or in response to large disruptions in the normal
behavior of the reactor, like sudden interruption of one of the feed streams.
It is therefore an object of the present invention to provide a polymerization process
occurring in a loop reactor wherein the polymer slurry is efficiently removed from the loop
reactor through sequentially operated settling legs. It is further an object of the present
invention to establish non-fluctuating reaction conditions in a reactor during a
polymerization process. More in particular, it is an object of the invention to preserve.,
pressure and to avoid pressure fluctuation in a polymerization reactor. Another object of
the present invention is to increase the reactor throughput by providing stable operation
conditions. A further object is to increase the monomer concentrations in the liquid
medium. Another object of the present invention is to increase the weight percent (wt %)
of polymer solids in the polymerization slurry circulating in the polymerization zone in the
loop reactor. It is a further object of the invention to provide a flexible process that can be
routinely converted to conventional settling leg removal mode in order to adapt to sudden
disruption of the operating conditions caused for example by sudden large modification of
the diluent or monomer feed throughput rates or start-up conditions.
Summary of the invention
These present objects are achieved by the processes according to the present invention.
In a first aspect the present invention therefore relates to a polymerization process for
producing olefin polymers in a loop reactor comprising two or more settling legs,

comprising the steps of introducing into the loop reactor one or more olefin reactants,
polymerization catalysts, diluents and, optionally, additives, and while circulating said
reactants, catalysts, diluents and optional additives,
polymerizing said one or more olefin reactants to produce a polymer slurry comprising
essentially liquid diluent and solid olefin polymer particles,
said process further comprising one or more cycles of:
(a) allowing said polymer slurry to settle into said settling legs, and
(b) sequentially discharging said settled polymer slurry from said two or more settling legs
out of the reactor, whereby the aggregate time of discharge of the legs is more than 50%,
preferentially more than 80% and most preferably more than 95% of the time interval
between two triggerings of the same settling leg.
Surprisingly, it has been found that such operation of the settling legs reduces significantly
the disadvantages of the batch operation of the settling legs and allows operation of the
reactor at much higher solids concentration. Hence concentrations of greater than 40
weight percent are possible in accordance with this invention.
Furthermore, the present invention also enables to establish non-fluctuating reaction
conditions in a reactor during a polymerization process. More in particular, the processes
according to the present invention allow to preserve pressure in the reactor at an
optimized value and to avoid pressure fluctuation in a polymerization reactor. In particular,
this feature is obtained by providing a process wherein the settling legs are alternatingly
opened and closed such that the settling legs are alternatingly discharged. By sequentially
opening and closing subsequent settlings legs, the process provides that the time when
no settling leg is open and when pressure builds up in the reactor is significantly reduced
and may even be absent, generating a pressure behavior of the reactor similar to the
pressure profile obtained during continuous take-out techniques.
The present invention will be farther disclosed in detail hereunder. The description is only
given by way of example and does not limit the invention. The reference numbers relate to
the hereto-annexed figures.

Brief description of the accompanying irawings
Figure 1 represents a schematic perspective view of a single loop polymerization reactor.

Figure 2A represents a flow diagram for settling legs operating according to the prior art.
Figure 2B represents a graph of the pressure measured as a function of time in a reactor
operating according to the prior ait
Figure 3A represents a flow diagram for settling legs operating according to an
embodiment of the present invention.
Figure 3B represents a graph of the pressure measured as a function of time in a reactor
operating according to the embodiment of the present invention corresponding to figure
3A.
Figure 4 represents a schematic perspective view of a double loop polymerization reactor.
Detailed description of the invention
This invention relates to an olefin polymerization process in a loop reactor utilizing a
diluent, so a to produce a product slurry of polymer and diluent. This invention more in
particular relates to a polymerization processes for the production of polymer, wherein a
polymerization effluent is formed which is a slurry of particulate polymer solids suspended
in a liquid medium, ordinarily the reaction diluent and unreacted monomers.
The present invention is applicable to any process producing an effluent comprising a
slurry of particulate polymer solids.suspended in a liquid medium comprising a diluent and
unreacted monomer. Such reaction processes include those which have come to be
known in the art as particle form polymerizations.
The settled polymer slurry may be discharged from said two or more settling legs through
discharge valves in a predetermined sequential pattern so that the aggregate time of
discharge for all the legs Is more than 50%, preferentially more than 80% and most
preferably more than 95% of the time between two triggerings of the same settling leg. In
a most preferred embodiment the aggregate time of discharge for all the legs is from 95%
to 100% of the time duration between two triggerings of the same settling leg.
As used herein the term "aggregate time of discharge" refers to the sum of the duration
over which the discharge valve of each settling leg is open, said sum being across all
settling legs and being limited to a single opening of each settling leg.
By keeping at least one settling leg open more than 50%, preferably more than 60%, most
likely more than 95% and most preferably 100 % of the time between two consecutive

triggerings of any single settling leg, fluctuations of reaction conditions in the reactor, and
in particular of pressure values, are significantly reduced and even may be avoided.
The present process comprises the step of maintaining a flow of settled polymer slurry out
of said reactor by sequentially discharging said settling leg.
The present process according to the invention provides several advantages over the
prior art including: allowing for a stable pressure profile of the product recovery zone (e.g.
a stable pressure profile at the gas outlet of the flash tank allows a better operation of the
recycle gas compressor); because of minor or even absent pressure drops of the reactor,
significantly increasing the maximum monomer concentration in the loop reactor liquid
medium thereby increasing reactor throughput; significantly increasing the wt % of
polymer solids in the polymerization slurry. Another advantage of the present processes is
an easier response to a sudden drop in reactor pressure, which can happen if the
monomer flow is quickly reduced. The present invention also enables to establish non-
fluctuating reaction conditions in a reactor during a polymerization process. More in
particular, the processes according to the present invention allow to preserve pressure in
the reactor at a certain value and to avoid pressure fluctuation in a polymerization reactor.
Furthermore, polymerization product slurry discharging operated according to the present
invention allows the monomers concentrations to be limited only by the monomer solubility
in the liquid diluent in the reactor, thereby increasing the specific reaction rate for
polymerization and increasing reactor throughput.
More in particular, the present invention relates to a polymerization process for the
manufacture of particulate olefin polymers consisting of the catalytic polymerization of
olefins such as C2 to C8 olefins in a diluent containing the monomer to be polymerized, the
polymerization slurry being circulated in a loop reactor to which the starting material is fed
and from which the polymer formed is removed. Examples of suitable monomers include
but are not limited to those having 2 to 8 carbon atoms per molecule, such as ethylene,
propylene, butylene pentene, butadiene, isoprene, 1-hexene and the like.
The polymerization reaction can be carried out at a temperature of from 50 to 120 8C,
preferably at temperature of from 70 to 115 °C, more preferably at temperature of from 80
to 110 °C, and at a pressure of from 20 to 100 bars, preferably at pressure of from 30 to
50 bars, more preferably at pressure of 37 to 45 bars.
In a preferred embodiment, present invention is particularly suitable for the polymerization
of ethylene in isobutane diluent. Suitable ethylene polymerization includes but is not

limited to homopolymerization of ethylene, copolymerization of ethylene and a higher 1-
olefin co-monomer such as 1-butene, 1-pentene, 1-hexene, 1-octene or 1-decene. In an
embodiment of the present invention, said co-monomer is 1-hexene.
Ethylene polymerizes in a liquid diluent in the presence of a catalyst, optionally a co-
catalyst, optionally co-monomer, optionally hydrogen and optionally other additives,
thereby producing a polymerization slurry.
As used herein, the term "polymerization slurry" or "polymer slurry" means substantially a
multi-phase composition including at least polymer solid particles and a liquid phase and
allow for a third phase (gas) to be at least locally present in the process, the liquid phase
being the continuous phase. The solids include catalyst and polymerized olefin, such as
polyethylene. The liquids include an inert diluent, such as isobutane, with dissolved
monomer such as ethylene and optionally, one or more co-monomers, molecular weight
control agents, such as hydrogen, antistatic agents, antifouling agents, scavengers, and
other process additives.
Suitable diluents (as apposed to solvents or monomers) are well known in the art and
include hydrocarbons which are inert or at least essentially inert and liquid under reaction
conditions. Suitable hydrocarbons include isobutane, n-butane, propane, n-pentane,
isopentane, neopentane, isohexane and n-hexane, with isobutane being preferred.
Suitable catalysts are well known in the art. Examples of suitable catalysts include but are
not limited to chromium oxide such as those supported on silica, organometal catalysts
including those known in the art as "Ziegler" or "Ziegler-Natta" catalysts, metallocene
catalysts and the like. The term "co-catalyst" as used herein refers to materials that can be
used in conjunction with a catalyst in order to improve the activity of the catalyst during the
polymerization reaction.
The polymerization slurry is maintained in circulation in a loop reactor comprising vertical
jacketed pipe sections connected through elbows. The polymerization heat can be
extracted by means of cooling water circulating in the jacket of the reactor. Said
polymerization may be performed in a single or in two or more loop reactors, which can be
used in parallel or in series. Said reactors operate in a liquid full mode. When used in
series they can be connected through means such as for example through one or more
settling legs of the first reactor.

The produced polymer is discharged according to the process of the present invention
from the loop reactor along with some diluent through two or more settling legs in which
the solid content is increased with respect to its concentration in the body of the reactor.
Sequentially discharging includes also the situations where said settling legs may be
alternately or simultaneously discharged.
According to an embodiment of the present invention, the rate of discharge of the polymer
slurry is such as to allow substantially uninterrupted outgoing flow from the loop reactor
(from the points of discharge of the polymer slurry through two or more settling legs and
also through the product recovery zone) equal to the in-going flow of feeds to the reactor.
As used herein the term "substantially uninterrupted" refers to a flow that can be
interrupted no more than 50 % of the time, preferably no more than 20 % of the time, most
preferably no more than 5% of the time.
The rate of discharge of the polymerization slurry out of the reactor and into a product
recovery zone is such as to maintain a pressure as constant as possible in the slurry
reactor and to eliminate intermittent low-pressure pulses associated with a more important
and more sudden discharge of a portion of the reactor contents that occurs with the
conventional batch operating settling legs on slurry reactors.
As used herein "product recovery zone" includes but is not limited to heated or not heated
flash lines, flash tank, cyclones, filters and the associated vapor recovery and solids
recovery systems or transfer lines to another reactor or said other reactor when several
reactors are connected in series.
When no reactor is present downstream of the settling legs, the extracted slurry may be
depressurized and transferred through for example heated or not heated flash lines to a
flash tank where the polymer and the unreacted monomer and/or co-monomer and diluent
are separated. The degassing of the polymer may be further completed in a purge
column.
When at least one reactor is present downstream of the settling legs the discharged slurry
is transferred through transfer lines to the next reactor. Transfer is made possible by
injecting the slurry in the downstream reactor in a point where the pressure is lower than
the pressure at the outlet of the settling legs.

Referring now to the drawings, Figure 1 schematically illustrates an example of a single
loop reactor 1 suitable for the polymerization process according to the invention. Said
polymerization process is carried out in said single loop reactor 1 which typically
comprises a plurality of interconnected pipes 7 such as a plurality of vertical pipe
segments, a plurality of upper lateral pipe segments, a plurality of lower lateral pipe
segments, wherein each of said vertical pipe segment is connected at an upper end
thereof to one of said upper lateral pipe segment and is connected at a lower end thereof
to one of said lower lateral pipe segments through elbow shaped connecting segments,
thus defining a continuous flow path for said slurry. It will be understood that while the
loop reactor 1 is illustrated with six vertical pipes, said loop reactor 1 may be equipped
with less or more pipes, such as 4 or more pipes, for example between 4 and 20 vertical
pipes. The vertical sections of the pipe segments 7 are preferably provided with heat
jackets 9. Polymerization heat can be extracted by means of cooling water circulating in
these jackets of the reactor. Reactants are introduced into the reactor 1 by line 3.
Catalyst, optionally in conjunction with a co-catalyst or activation agent, is injected in the
reactor 1 by means of the conduit 10. In a preferred embodiment, catalysts are introduced
through conduit 10 just upstream from the circulation pump, and diluent, monomer,
optional co-monomers and reaction additives are introduced through line 3 just
downstream of the circulation pump.
The polymerization slurry is directionally circulated throughout the loop reactor 1 as
illustrated by the arrows 6 by one or more pumps, such as axial flow pump 2. The pump
may be powered by an electric motor 5. As used herein the term "pump" includes any
device from compressing driving, raising the pressure of a fluid, by means for example of
a piston or set of rotating impellers 4.
The reactor 1 is further provided with two or more settling legs connected to the pipes 7 of
the reactor 1. Polymerization slurry may be removed from the loop reactor by discharge of
the slurry settled in said two or more settling legs into one or more product recovery lines
8, e.g. into a product recovery zone.
As illustrated in Figure 1, one of the horizontal sections of the loop reactor is equipped
with four settling legs A, B, C and D. In a preferred embodiment the processes according
to the present invention are performed in a loop reactor comprising at least two settling
legs. In another embodiment the processes according to the present invention are
performed in a loop reactor comprising 2 to 20 settling legs, preferably 4 to 12 settling
legs, more preferably 6 to 10 settling legs. The settling legs can be located on any

segment or any elbow of said reactor. In said settling legs the polymerization slurry settles
so that the slurry exiting the reactor is more concentrated in solid than the circulating
slurry. This permits to limit the quantity of diluent that has to be treated and re-fed to the
reactor for example for the last reactor of a multiple reactor set-up. This also limits the
transfer of reactants into the next reactor, which should be minimum when loop reactors
are in series as mentioned in patent EP 649 860. It will be understood that the discharge
of said settling legs may be operated in a continuous sequential or discontinuous mode,
but preferably in a sequential mode.
The settling legs are preferably provided with isolation valves 11. These valves 11 may be
ball valves lor example. These valves 11 are open under normal conditions and can be
closed for example to isolate a settling leg from operation.. Said valves can be closed
when the reactor pressure falls below a chosen value. Furthermore, the settling legs can
be provided with product take off or discharge valves 12.
In an embodiment of the present invention, the discharging is obtained by synchronizing
the opening and closing time of the discharge valve 12 of each settling leg thereby
maintaining a flow of settled polymer slurry out of said reactor.
The discharge valve 12 that can be used in this invention may be any type of valve which
can permit efficient discharge of a polymer slurry, when it is fully open. An angle valve, or
ball valves may be suitably used. For example, the valve may have such a structure that
solid matter is prevented from accumulating or precipitating at the main body portion of
the valve. However, the type and structure of the discharge valve can be selected by
those skilled in the art as required. A part or the totality of the leg is discharged at each
opening of the discharge valve.
In a preferred embodiment, the discharge from each individual settling leg is adjusted so
that the amount of settled slurry discharged through the valve into the product recovery
zone is less than 10% larger or smaller than the amount that settles in said individual leg
between two consecutive openings of said valve.
Referring now to Figure 2A, said Figure represents a flow diagram for settling legs
operating according to the prior art. Time is along the abscissa. Each line represents the
status 0 of one of the settling leg. For this schematic drawing, four legs A, B; C and D are
considered. This number of legs is taken as a matter of example but the method applies to
any number of legs larger than one. Each of the four lines has two levels: a low level
indicating that that particular leg is closed and a high level indicating that it is open. In this

prior art, there is a time interval during which the settling legs are closed and the polymer
slurry is not discharged. During such period of time the pressure in the reactor
continuously increases due to continuous injection of feed into the reactor. In Figure 2B a
graph illustrating the influence of said discontinuous discharging flow on the pressure in
the loop reactor is shown. The pressure is not kept constant and varies greatly between
two discharging period. The pressure increases when all the legs are closed and
decreases quickly when one leg opens. Pressure fluctuations AP in said loop reactor may
be as high as 1 bar. Said pressure fluctuation causes many problems such as
perturbations of the flow pattern, the risk of creation of gas bubbles in the reactor, due to
the pressure dependency of the monomer solubility in the diluent, thereby limiting the
productivity of the polymerization process. Thus, discontinuous discharge has the further
disadvantage of limiting the concentration of the monomers in the loop reactor.
Figure 3A represents a flow diagram for settling legs operating according to an
embodiment of the present invention with sequential discharging of the legs. In this
particular embodiment, when a given settling leg closes, the following one opens. In this
embodiment, there is always one leg open. The rate of discharge of the polymer slurry is
such as to maintain a flow of said settled slurry from said settling legs according to a
preferred embodiment. In this preferred embodiment, the aggregate time of discharge for
all the legs is equal to 100% of the time interval between two triggerings of the same
settling leg.
Figure 3B is a graph illustrating the influence of said sequential discharging with
substantially uninterrupted flow on the pressure in the loop reactor is shown according to
a preferred embodiment of the present invention. The rate of discharge of said settled
slurry is such as to maintain a constant pressure in the slurry reactor and to eliminate
intermittent low-pressure pulses associated with a more important and more sudden
discharge of a portion of the reactor contents that occurs with the conventional batch
operating settling legs on slurry reactors (Figure 2A).
In a preferred embodiment, the opening/closing of each settling leg as well as the
discharge aperture of each settling leg is adjusted and synchronized so as to maintain a
constant pressure in the reactors. In another preferred embodiment, the opening/closing
of each settling leg as well as the discharge aperture of each settling leg is adjusted so
that the aggregate time of opening for all the legs is more than 50%, preferentially more
than 80%, preferably more than 95%, most preferably is 95% to 105% of the time interval
between two triggerings of the same settling leg.

As illustrated on said Figure 3A the opening time of a settling leg coincide with the closing
time of a subsequent settling leg, such sequence carries until the last settling leg has
been discharged, and the cycle starts again as to maintain a flow of settled slurry out of
said reactor which is substantially uninterrupted.
More in particular, discharging of said polymer slurry from each settling leg sequentially is
performed in such a way that once the last settling leg has been discharged the first
settling leg is discharged again, said process further comprising one or more cycles of:
(i) closing the discharge valve of a settling leg while simultaneously opening the discharge
valve of another settling leg,
(ii) adjusting the flow through the discharge valves of said two or more settling legs so as
to regulate the mass balance of the slurry within the reactor. This flow adjustment may be
obtained, as an example, by adjusting the aperture of the discharge valve or of any flow-
regulating device located close to the discharge valve.
The sequential opening cycle time of the discharge valve of each settling legs according
to the present invention allows to maintain a constant pressure in the reactor.
Adjusting the aperture of the discharge valve of the settling leg includes but is not limited
to reducing or enlarging the size of the opening of the discharge valve, or adding
downstream of said discharge valve another flow regulating device of adjustable smaller
aperture or an adjustable reduction of smaller aperture.
In an embodiment of the present process, the opening of a settling leg is triggered by the
closing of another settling leg and the closing of a settling leg triggers the opening of
another settling leg.
More in particular, the discharging is adjusted in such a way that the closing of a first
settling leg and the opening of a subsequent settling leg start at the same time.
According to the present invention, the synchronizing and the triggering of the opening
and closing of said settling legs are controlled by computational means. These
computational means allow the adjustment and the control of the periodical opening at
predetermined frequencies and sequence of the settling legs to maintain a flow of said
settled slurry out of said reactor which is substantially uninterrupted. Other control means
such as pressure or temperature controllers and flow controllers, flow transducers and
flow sensors may be used to further fine-tune the discharging process

The present invention encompasses different types of control means which accomplish
the purpose of the invention. The invention is also applicable to mechanical, hydraulic or
other signal means for transmitting information, in almost all control systems some
combination of electrical, pneumatic, mechanical or hydraulic signals will be used.
However, use of any other type of signal transmission, compatible with the process and
equipment in use, is within the scope of the invention.
The actuation and the control of the discharging step can be implemented using electrical
analog, digital electronic, pneumatic, hydraulic, mechanical or other similar types of
equipment or combinations of one or more such equipment types. A computational means
is used in the preferred embodiment of this invention to operate and control the process
parameters. Computers or other types of computing devices can be used in the invention.
The present invention also relates to computational means comprising a process
controller operatively connected to the discharge valves of said settling legs.
The present invention further relates to a process for sequentially discharging through two
or more settling legs, polymer slurry from a loop reactor so as to obtain a substantially
uninterrupted flow of said slurry into a product recovery zone said process comprising the
step of discharging said settled polymer slurry from said two or more settling legs through
discharge valves in a predetermined sequential pattern so that the aggregate time of
opening for all the legs is more than 50%, preferentially more than 80% and most
preferably more than 95% of the time interval between two triggerings of the same settling
leg.
The polymerization process according to the invention may further be performed in
multiple loop reactors such as for example in a double loop reactor as illustrated in Figure
4.
Figure 4 represents two single loop reactors 100, 116, which are interconnected in series.
Both reactors 100, 116 consist of a plurality of interconnected pipes 104. The vertical
sections of the pipe segments 104 are preferably provided with heat jackets 105.
Reactants are introduced into the reactors 100 by line 107. Catalyst, optionally in
conjunction with a co-catalyst or activation agent, may be injected in one or both of the
reactors 100 and 116 by means of conduit 106. The polymerization slurry is directionally
circulated throughout the loop reactors 100, 116 as illustrated by the arrows 108 by one or
more pumps, such as axial flow pump 101. The pumps may be powered by an electric
motor 102. The pumps may be provided with set of rotating impellers 103. The first reactor

100, is further provided with two or more settling legs 109 connected to the pipes 104 of
said reactor 100. The second reactor 116 is further provided with one or more settling legs
109 connected to the pipes 104 of said reactor 116. Said second reactor 116 can be
conventionally discharged. In a preferred embodiment, said second reactor 116 is
provided with two or more settling legs 109 which are discharged according to
embodiments of the present invention. The settling legs 109 are preferably provided with
an isolation valve 110. Further the settling legs can be provided with product take off or
discharge valves 111 or can be in direct communication with the downstream section.
Downstream the exit of the settling leg 109 of reactor 100, a transfer line 112 is provided
which allows to transfer polymer slurry settled in the settling legs 109 to the other reactor
116, preferably through a piston valve 115. Along the transfer line 112, a three-way valve
114 may divert the flow to a product recovery zone if the multiple loop reactor has to be
used in a parallel configuration. Polymer slurry settled in the settling legs 109 of reactor
116 can be removed by means of one or more product recovery lines 113, e.g. to a
product recovery zone.
It has been observed that by sequentially discharging settled polymer slurry from a loop
reactor according to the present process, higher weight percent solids can be circulated in
the reactor. Furthermore, increased weight percent solids in the loop reactor increases
catalyst residence time, increases catalyst productivity. Higher catalyst productivity also
increase the weight percent solids removed from the reactor which reduces the diluent
processing cost in recycle equipment. In addition the present invention enables to
establish non-fluctuating reaction conditions in a reactor during a polymerization process.
More in particular, the processes according to the present invention allow to preserve
pressure in the reactor at a certain value and to avoid pressure fluctuation in a
polymerization reactor. Furthermore, the process according to the present invention also
reduces the pressure fluctuations in the flash tank and the inlet of the recycle compressor
what induces benefits in the reliability of said compressor. Furthermore, polymerization
product slurry discharging operated according to the present invention allows the
monomers concentrations to be adjusted by the monomer solubility in the liquid diluent in
the reactor at a higher reference pressure, thereby increasing the specific reaction rate for
polymerization and increasing the reactor throughput.
Although the present invention has been described with considerable detail with reference
to certain preferred variations thereof, other variations are possible. Therefore, the spirit
and scope of the appended claims should not be limited to the preferred variations
described herein.

We Claim:
1. Polymerization process for producing olefin polymers in a loop reactor comprising two
or more settling legs, comprising the steps of :
- introducing into the loop reactor one or more olefin reactants, polymerization
catalysts and diluents, and while circulating said reactants, catalysts and diluents;
- polymerizing said one or more olefin reactants to produce a polymer slurry
comprising essentially liquid diluent and solid olefin polymer particles;
said process further comprising one or more cycles of:
(a) allowing said polymer slurry to settle into said settling legs, and
(b) sequentially discharging said settled polymer slurry from said two or more settling
legs out of the reactor, whereby the aggregate time of discharge of all the legs is more
than 50%, preferentially more than 80% and most preferably more than 95% of the
time interval between two triggerings of the same settling leg.

2. Process as claimed in claim 1, wherein the step of sequentially discharging said
settled polymer slurry from said two or more settling legs out of the reactor, whereby
the aggregate time of discharge of all the legs is from 95% to 105% of the time interval
between two triggerings of the same settling leg.
3. Process as claimed in claim 1 or 2, wherein the step of maintaining a flow of settled
polymer slurry out of said reactor by sequentially discharging said settling leg.
4. Process as claimed in any of claims 1 to 3, wherein the discharging is obtained by
synchronizing the opening and closing time of the discharge valve of each settling leg
thereby maintaining a flow of settled polymer slurry out of said reactor.
5. Process as claimed in any of claims 1 to 4, wherein the step of adjusting the discharge
from each individual settling leg so that the amount of settled slurry discharged
through the valve into the product recovery zone is less than 10% larger or smaller
than the amount that settles in said individual leg between two consecutive openings
of said valve.
6. Process as claimed in any of claims 1 to 5, wherein the discharging of said polymer
slurry from each settling leg is sequentially performed in such a way that once the last

settling leg has been discharged the first settling leg is discharged again, said process
further comprising one or more cycles of:
(i) closing the discharge valve of a settling leg while simultaneously opening the
discharge valve of another settling leg,
(ii) adjusting the flow through the discharge valves of said two or more settling legs so
as to regulate the mass balance of the slurry within the reactor.
7. Process as claimed in claim 6, wherein said flow adjustment is obtained, by adjusting
the aperture of the discharge valve or of a flow regulating device.
8. Process as claimed in any of claims 1 to 7, wherein the opening of a settling leg is
triggered by the closing of another settling leg
9. Process as claimed in to any of claims 1 to 8, wherein the closing of a first settling leg
and the opening of a subsequent settling leg start at the same time.
10. Process as claimed in any of claims 1 to 9, wherein the opening of a first settling leg
coincides with the closing of another settling leg.
11. Process as claimed in any of claims 1 to 10, wherein the opening and closing of each
settling leg is performed by actuating the discharges valve comprised on each settling
leg.
12. Process as claimed in any of claims 1 to 11, wherein the synchronizing and the
triggering of the opening and closing of said settling legs are controlled by
computational means.
13. Process as claimed in any of claims 1 to 12, wherein said process is performed in a
loop reactor comprising 2 to 20 settling legs, preferably 4 to 12 settling legs, more
preferably 6 to 10 settling legs.
14. Process as claimed in any of claims 1 to 13, wherein said process is performed in
double loop reactors connected in series.


The present invention relates to a polymerization process for producing olefin polymers in a loop reactor comprising
two or more settling legs, comprising the steps of: - introducing into the loop reactor one or more olefin reactants, polymerization
catalysts and diluents, and while circulating said reactants, catalysts and diluents; - polymerizing said one or more olefin reactants
to produce a polymer slurry comprising essentially liquid diluent and solid olefin polymer particles; said process further comprising
one or more cycles of: (a) allowing said polymer slurry to settle into said settling legs, and (b) sequentially discharging said settled
polymer slurry from said two or more settling legs out of the reactor, whereby the aggregate time of discharge of all the legs is more
than 50%, preferentially more than 80% and most preferably more than 95% of the time interval between two triggerings of the same
setding leg.

Documents:

02062-kolnp-2006-abstract.pdf

02062-kolnp-2006-assignment.pdf

02062-kolnp-2006-claims.pdf

02062-kolnp-2006-correspondence others.pdf

02062-kolnp-2006-description(complete).pdf

02062-kolnp-2006-drawings.pdf

02062-kolnp-2006-form-1.pdf

02062-kolnp-2006-form-3.pdf

02062-kolnp-2006-form-5.pdf

02062-kolnp-2006-internationl publication.pdf

02062-kolnp-2006-internationl search authority report.pdf

02062-kolnp-2006-priority document.pdf

2062-KOLNP-2006-ABSTRACT 1.1.pdf

2062-KOLNP-2006-AMANDED CLAIMS.pdf

2062-kolnp-2006-assignment.pdf

2062-KOLNP-2006-CANCELLED PAGES.pdf

2062-kolnp-2006-correspondence.pdf

2062-KOLNP-2006-DESCRIPTION (COMPLETE) 1.1.pdf

2062-KOLNP-2006-DRAWINGS 1.1.pdf

2062-kolnp-2006-examination report.pdf

2062-KOLNP-2006-FORM 1 1.1.pdf

2062-kolnp-2006-form 18.1.pdf

2062-kolnp-2006-form 18.pdf

2062-KOLNP-2006-FORM 2.pdf

2062-KOLNP-2006-FORM 3 1.1.pdf

2062-kolnp-2006-form 3.pdf

2062-kolnp-2006-form 5.pdf

2062-KOLNP-2006-FORM-27.pdf

2062-kolnp-2006-gpa.pdf

2062-kolnp-2006-granted-abstract.pdf

2062-kolnp-2006-granted-claims.pdf

2062-kolnp-2006-granted-description (complete).pdf

2062-kolnp-2006-granted-drawings.pdf

2062-kolnp-2006-granted-form 1.pdf

2062-kolnp-2006-granted-form 2.pdf

2062-kolnp-2006-granted-specification.pdf

2062-KOLNP-2006-OTHERS.pdf

2062-kolnp-2006-others1.1.pdf

2062-KOLNP-2006-PETITION UNDER RULE 137.pdf

2062-KOLNP-2006-REPLY TO EXAMINATION REPORT.pdf

2062-kolnp-2006-reply to examination report1.1.pdf


Patent Number 249630
Indian Patent Application Number 2062/KOLNP/2006
PG Journal Number 44/2011
Publication Date 04-Nov-2011
Grant Date 31-Oct-2011
Date of Filing 21-Jul-2006
Name of Patentee TOTAL PETROCHEMICALS RESEARCH FELUY
Applicant Address ZONE INDUSTRIELLE C, B-7181 SENEFFE (FELUY)
Inventors:
# Inventor's Name Inventor's Address
1 FOUARGE LOUIS SLEUTELPASSTRAAT, 4, B-1700 DILBEEK
PCT International Classification Number C08F 2/14
PCT International Application Number PCT/EP2005/050542
PCT International Filing date 2005-02-08
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 04100582.8 2004-02-13 EUROPEAN UNION