Title of Invention	"METHOD FOR THE PREPARATION OF LINEAR ALPHA-OLEFINS"
Abstract	The present invention relates to a method for the preparation of linear alpha-olefms by oligomerization of ethylene in a reactor in the presence of a solvent and a catalyst, characterized in that from a discharge stream of the reactor comprising the solvent, catalyst, linear alpha-olefins and substantially high molecular weight oligomers, the high molecular weight oligomers are separated, then diluted with a dilution medium and heated to about 13O°C to about 200°C, the diluted high molecular weight oligomers being then transferred to a disposal device, wherein recycles for loop operation are established, and flow rates of the loop streams are from about 1 to about 50 m3/h; and a reactor system therefore.

Title of Invention

"METHOD FOR THE PREPARATION OF LINEAR ALPHA-OLEFINS"

Abstract

The present invention relates to a method for the preparation of linear alpha-olefms by oligomerization of ethylene in a reactor in the presence of a solvent and a catalyst, characterized in that from a discharge stream of the reactor comprising the solvent, catalyst, linear alpha-olefins and substantially high molecular weight oligomers, the high molecular weight oligomers are separated, then diluted with a dilution medium and heated to about 13O°C to about 200°C, the diluted high molecular weight oligomers being then transferred to a disposal device, wherein recycles for loop operation are established, and flow rates of the loop streams are from about 1 to about 50 m3/h; and a reactor system therefore.

Full Text	Method for the preparation of linear alpha-olefins and reactor system therefore with improved disposal of high molecular weight oligomers The present invention relates to a method for the preparation of linear alpha-olefins by oli-gomerization of ethylene in a reactor in the presence of a solvent and a catalyst. Oligomerization methods for preparing linear alpha-olefms are widely known in the art. This method is usually carried out in the presence of a catalyst preferably comprising a zirconium component, such as zirconium tetraisobutyrate, and an aluminum component as activator, such as ethyl aluminum sesquichloride. One problem associated with such oligomerization methods is that not only liquid linear alpha-olefms with desired chain length, e.g. C4-C18, are prepared, but also high molecular weight oligomers which are solid at reaction temperature of about 60-100°C and have to be removed from the plant to avoid plugging. Such high molecular weight oligomers may be separated from the desired alpha-olefin products. A further problem is the disposal of high molecular weight oligomers from the plant, as the amount of high molecular weight oligomers produced is low (some kg/h) and it is often required to transfer the high molecular weight oligomers over a large distance to a disposal device. In the piping connecting the reactor unit and the disposal device, such as an incinerator, as well as in any equipment and piping which are in contact with high molecular weight oligomers containing streams, plugging may occur. This plugging may also occur due to the low flow rates in the reactor system. In some cases, the distance between the oligomerization reactor and the disposal device is large, for example, about 1 to about 2 kilometers. Thus, small amounts of high molecular weight oligomers (in the range of some kilogram/h) are difficult to transfer to the disposal device due to long residence time, and this often results in plugging of equipment and piping. It is therefore an object of the present invention to provide a method for the preparation of linear alpha-olefms which overcomes the disadvantages of the prior art, especially a method shall be provided which avoids plugging of equipment and piping which are in contact with high molecular weight oligomers containing streams. Tif is object is achieved in that a discharge stream of the reactor comprising the solvent, catalyst, linear alpha-olefins and substantially high molecular weight oligomers, the high molecular weight oligomers are separated, then diluted with a dilution medium and heated to about 130°C to about 200°C, the diluted high molecular weight oligomers being then transferred to a disposal device, wherein recycles for loop operation are established, and flow rates of the loop -streams are from about 1 to about 50 m3/h. Preferably, the high molecular weight oligomers are separated in a separation unit, preferably a filter unit or a distillation unit. Preferably, the temperature in the reactor is from about 60 to about 100°C. The solvent may be toluene and the dilution medium may be toluene and/or a liquid fraction of the oligomerization product comprising oligomers having more than 18 carbon atoms. In one preferred embodiment, the dilution medium comprises the bottom product of a purification apparatus, preferably a distillation column, for the solvent. The dilution medium may comprise high molecular weight oligomers. The method is further characterized in that the dilution medium with dissolved high molecular weight oligomers is recycled in a loop to increase flow rates from kg/h to m3/h with corresponding stream velocities to avoid plugging of lines. Preferably, the disposal device is an incinerator. It is also proposed that the high molecular weight oligomers containing streams are agitated. Additionally, the dilution ratio of the dilution medium: high molecular weight oligomer may be about 5:1 to about 15:1, preferably about 10:1. Finally, according to the invention a reactor system for preparing linear alpha-olefms is provided, especially by an inventive method, comprising a reactor, a separation unit for separating high molecular weight oligomers, recycle loops, and a transfer line to a disposal device. Surprisingly, it was found that especially due to the dilution of the high molecular weight oligomers with dilution medium and heating thereof to higher temperatures, plugging of equipment and piping which are in contact with high molecular weight oligomers containing streams can be substantially avoided. Further, no handling of high viscous/solid materials is necessary. Due to the low concentration of the high molecular weight oligomers in the dilution medium, the heat tracing requirements in the inventive method are substantially reduced. Further, the plant availability and reliability in which the oligomerization method is conducted are improved. It is obvious that the inventive method is not necessarily restricted to the oligomerization of ethyiene to obtain linear alpha-olefms, but may be utilized in all technologies handling high molecular weight oligomers. Additional features and advantages of the inventive method are now illustrated in detail with reference to the accompanying drawing wherein Fig. 1 shows a schematic illustration of the inventive method for the preparation of linear alpha-olefms. In Fig. 1 a reactor 1 for the oligomerization of ethyiene to prepare linear alpha-olefms is provided. In the reactor 1 ethyiene is oligomerized in the presence of a solvent and a catalyst, preferably at a temperature of about 60-100°C. After oligomerization (the reactor is preferably operated continuously), a discharge stream is removed from the reactor via a discharge line 2. The discharge stream comprises the solvent, catalyst, liquid linear alpha-olefms and High molecular weight oligomers. The term "high molecular weight oligomers" is meant to comprise oligomers having such a high molecular weight that they are substantially solid at reaction temperature. Additionally, further discharge and feed lines are connected to the reactor, but are omitted for purposes of clarity. The discharge stream may be transferred via the discharge line 2 to a separation unit 3, also held at a temperature of about 60-100°C, wherein solid high molecular weight oligomers are separated from the liquid discharge stream.- The separation unit may be a filter or any other means suitable and known for someone skilled in the art. Such a separation unit is not absolutely necessary, for example, if no high molecular weight oligomers being solid at reaction temperature are present. The discharge stream containing the substantial amount of solvent and liquid linear alpha-olefins may be processed as is known for someone skilled in the art, for example by distillation of the respective linear alpha-olefins. The solvent utilized for the oligomerization process is preferably toluene. Toluene is provided to and removed from the reactor by a reactor flushing system 4. The reactor flushing system 4 is further connected to a solvent purification apparatus 5, preferably a distillation equipment. In the solvent purification apparatus 5, the solvent may be purified and purified solvent may be reintroduced into the reactor 1. Impurities which may be incorporated in the solvent may be also high molecular weight oligomers which arc collected in the bottoms product of the solvent purification apparatus 5. The bottom product may be used as dilution medium. Separated high molecular weight oligomers are passed via line 6. Additionally, the bottom product comprising also high molecular weight oligomers is removed from the solvent purification apparatus 5 via line 7. Lines 6 and 7 are combined. The combined streams are then heated to a temperature of about 130°C to about 200°C so that the high molecular weight oligomers may be diluted or melted (as polyethylene being a major component of the high molecular weight oligomers has a melting point of about 130°C). Preferably, the weight ratio of high molecular weight oligomers and dilution medium is from about 1:5 to about 1:15, preferably 1:10. In a preferred embodiment, the high molecular weight oligomers containing streams are also agitated. The combined streams may be then transferred via line 8 to a tank 9 where the combined streams may be additionally diluted with further dilution medium. Also, fractions of the linear alpha-olefins having more than 18 carbon atoms may be added at this stage, or even earlier or later. As it is still difficult to find economically attractive applications for the fractions of C20+ these fractions may be preferably utilized to dilute the high molecular weight oligomers for disposal. From the tank 9 the diluted high molecular weight oligomers may be then transferred via line 10 to a disposal device, preferably an incinerator 11. From line 10 the diluted high molecular weight oligomers may be also recycled via recycle line 12 into tank 9. The effluent of tank 9 may be also recycled via recycle line 13 to lines 6 and 7. Utilizing the inventive method, high molecular weight oligomers containing streams are diluted with an appropriate dilution medium, kept at elevated temperature and, optionally, agitated. In the inventive method, stream velocities in the equipment and piping may be kept high by establishing of larger pump flow rates which are in the range of about 1 to about 50 m3/h. Due to the high stream velocities any plugging of equipment and piping may be avoided. Additionally, the viscosity and pressure drop of the piping system can be adjusted by the dilution rate of the high molecular weight oligomers in the dilution medium. Thus, the small amounts of high molecular weight oligomers (in the range of some kg/h) obtained in the inventive method may be easily disposed by dilution and heating with prevention of plugging. The features disclosed in the foregoing description, in the drawing or in the claims may, both separately and in any combination thereof, be material for realizing the invention in diverse forms thereof. WE CLAIM: 1. Method for the preparation of linear alpha-olefins by oligomerization of ethylene in a reactor in the presence of a solvent and a catalyst, characterized in that from a discharge stream of the reactor comprising the solvent, catalyst, linear alpha-olefins and substantially high molecular weight oligomers being substantially solid at reaction temperature, the high molecular weight oligomers are separated in a separation unit and are then diluted with a dilution medium and heated at 130°C to 200°C, whereupon the diluted high molecular weight oligomers are thcn transferred to a disposal device, wherein a part of the diluted high molecular weight oligomers is disposed and another part thereof is recycled in a loop downstream the separation unit, wherein flow rates of the loop streams are from 1 to 50 m3/h. 2. Method as claimed in claim I , wherein the high molecular weight oligomers arc separated in a filter unit or a distillation unit. 3. Method as claimed in claim 1, wherein the temperature in the reactor is from 60 to 1 OO°C. 4. Method as claimed in any of the preceding claims, wherein the solvent is toluene. 5. Method as claimed in any of the preceding claims, wherein the dilution medium is toluene and/or a liquid fraction of the oligomerization product comprising oligomers having Inore than 18 carbon atoms. 6. Method as claimed in any of the preceding claims, wherein the dilution lnediurn comprises the bottom product ofa purification apparatus, preferably a distillation column, for the solvent. 7. Method as claimed in any of the preceding claims, wherein the dilution medium with dissolved high molecular weight oligomers is recycled in a loop. 8. Method as claimed in any of the preceding claims, wherein the disposal device is an incinerator. 9.Mcthod as claimed in any of the preceding claims, wherein the dilution ratio of the dilution medium: high molecular weight oligomer is 5: 1 to 15: 1, preferably 10: 1.

Full Text

Method for the preparation of linear alpha-olefins and reactor system therefore with improved disposal of high molecular weight oligomers
The present invention relates to a method for the preparation of linear alpha-olefins by oli-gomerization of ethylene in a reactor in the presence of a solvent and a catalyst. Oligomerization methods for preparing linear alpha-olefms are widely known in the art. This method is usually carried out in the presence of a catalyst preferably comprising a zirconium component, such as zirconium tetraisobutyrate, and an aluminum component as activator, such as ethyl aluminum sesquichloride. One problem associated with such oligomerization methods is that not only liquid linear alpha-olefms with desired chain length, e.g. C4-C18, are prepared, but also high molecular weight oligomers which are solid at reaction temperature of about 60-100°C and have to be removed from the plant to avoid plugging. Such high molecular weight oligomers may be separated from the desired alpha-olefin products. A further problem is the disposal of high molecular weight oligomers from the plant, as the amount of high molecular weight oligomers produced is low (some kg/h) and it is often required to transfer the high molecular weight oligomers over a large distance to a disposal device. In the piping connecting the reactor unit and the disposal device, such as an incinerator, as well as in any equipment and piping which are in contact with high molecular weight oligomers containing streams, plugging may occur. This plugging may also occur due to the low flow rates in the reactor system. In some cases, the distance between the oligomerization reactor and the disposal device is large, for example, about 1 to about 2 kilometers. Thus, small amounts of high molecular weight oligomers (in the range of some kilogram/h) are difficult to transfer to the disposal device due to long residence time, and this often results in plugging of equipment and piping. It is therefore an object of the present invention to provide a method for the preparation of linear alpha-olefms which overcomes the disadvantages of the prior art, especially a method shall be provided which avoids plugging of equipment and piping which are in contact with high molecular weight oligomers containing streams. Tif is object is achieved in that a discharge stream of the reactor comprising the solvent, catalyst, linear alpha-olefins and substantially high molecular weight oligomers, the high molecular weight oligomers are separated, then diluted with a dilution medium and heated to about 130°C to about 200°C, the diluted high molecular weight oligomers being then transferred to a disposal device, wherein recycles for loop operation are established, and flow rates of the loop -streams are from about 1 to about 50 m3/h. Preferably, the high molecular weight oligomers are separated in a separation unit, preferably a filter unit or a distillation unit. Preferably, the temperature in the reactor is from about 60 to about 100°C. The solvent may be toluene and the dilution medium may be toluene and/or a liquid fraction of the oligomerization product comprising oligomers having more than 18 carbon atoms. In one preferred embodiment, the dilution medium comprises the bottom product of a purification apparatus, preferably a distillation column, for the solvent. The dilution medium may comprise high molecular weight oligomers. The method is further characterized in that the dilution medium with dissolved high molecular weight oligomers is recycled in a loop to increase flow rates from kg/h to m3/h with corresponding stream velocities to avoid plugging of lines. Preferably, the disposal device is an incinerator. It is also proposed that the high molecular weight oligomers containing streams are agitated. Additionally, the dilution ratio of the dilution medium: high molecular weight oligomer may be about 5:1 to about 15:1, preferably about 10:1. Finally, according to the invention a reactor system for preparing linear alpha-olefms is provided, especially by an inventive method, comprising a reactor, a separation unit for separating high molecular weight oligomers, recycle loops, and a transfer line to a disposal device. Surprisingly, it was found that especially due to the dilution of the high molecular weight oligomers with dilution medium and heating thereof to higher temperatures, plugging of equipment and piping which are in contact with high molecular weight oligomers containing streams can be substantially avoided. Further, no handling of high viscous/solid materials is necessary. Due to the low concentration of the high molecular weight oligomers in the dilution medium, the heat tracing requirements in the inventive method are substantially reduced. Further, the plant availability and reliability in which the oligomerization method is conducted are improved. It is obvious that the inventive method is not necessarily restricted to the oligomerization of ethyiene to obtain linear alpha-olefms, but may be utilized in all technologies handling high molecular weight oligomers. Additional features and advantages of the inventive method are now illustrated in detail with reference to the accompanying drawing wherein Fig. 1 shows a schematic illustration of the inventive method for the preparation of linear alpha-olefms.
In Fig. 1 a reactor 1 for the oligomerization of ethyiene to prepare linear alpha-olefms is provided. In the reactor 1 ethyiene is oligomerized in the presence of a solvent and a catalyst, preferably at a temperature of about 60-100°C. After oligomerization (the reactor is preferably operated continuously), a discharge stream is removed from the reactor via a discharge line 2. The discharge stream comprises the solvent, catalyst, liquid linear alpha-olefms and
High molecular weight oligomers. The term "high molecular weight oligomers" is meant to comprise oligomers having such a high molecular weight that they are substantially solid at reaction temperature. Additionally, further discharge and feed lines are connected to the reactor, but are omitted for purposes of clarity. The discharge stream may be transferred via the discharge line 2 to a separation unit 3, also held at a temperature of about 60-100°C, wherein solid high molecular weight oligomers are separated from the liquid discharge stream.- The separation unit may be a filter or any other means suitable and known for someone skilled in the art. Such a separation unit is not absolutely necessary, for example, if no high molecular weight oligomers being solid at reaction temperature are present. The discharge stream containing the substantial amount of solvent and liquid linear alpha-olefins may be processed as is known for someone skilled in the art, for example by distillation of the respective linear alpha-olefins.
The solvent utilized for the oligomerization process is preferably toluene. Toluene is provided to and removed from the reactor by a reactor flushing system 4. The reactor flushing system 4 is further connected to a solvent purification apparatus 5, preferably a distillation equipment. In the solvent purification apparatus 5, the solvent may be purified and purified solvent may be reintroduced into the reactor 1. Impurities which may be incorporated in the solvent may be also high molecular weight oligomers which arc collected in the bottoms product of the solvent purification apparatus 5. The bottom product may be used as dilution medium.
Separated high molecular weight oligomers are passed via line 6. Additionally, the bottom product comprising also high molecular weight oligomers is removed from the solvent purification apparatus 5 via line 7. Lines 6 and 7 are combined. The combined streams are then heated to a temperature of about 130°C to about 200°C so that the high molecular weight oligomers may be diluted or melted (as polyethylene being a major component of the high molecular weight oligomers has a melting point of about 130°C). Preferably, the weight ratio of high molecular weight oligomers and dilution medium is from about 1:5 to about 1:15, preferably 1:10. In a preferred embodiment, the high molecular weight oligomers containing streams are also agitated. The combined streams may be then transferred via line 8 to a tank 9 where the combined streams may be additionally diluted with further dilution medium. Also, fractions of the linear alpha-olefins having more than 18 carbon atoms may be added at this stage, or even earlier or later. As it is still difficult to find economically attractive applications
for the fractions of C20+ these fractions may be preferably utilized to dilute the high molecular weight oligomers for disposal. From the tank 9 the diluted high molecular weight oligomers may be then transferred via line 10 to a disposal device, preferably an incinerator 11. From line 10 the diluted high molecular weight oligomers may be also recycled via recycle line 12 into tank 9. The effluent of tank 9 may be also recycled via recycle line 13 to lines 6 and 7.
Utilizing the inventive method, high molecular weight oligomers containing streams are diluted with an appropriate dilution medium, kept at elevated temperature and, optionally, agitated. In the inventive method, stream velocities in the equipment and piping may be kept high by establishing of larger pump flow rates which are in the range of about 1 to about 50 m3/h. Due to the high stream velocities any plugging of equipment and piping may be avoided. Additionally, the viscosity and pressure drop of the piping system can be adjusted by the dilution rate of the high molecular weight oligomers in the dilution medium. Thus, the small amounts of high molecular weight oligomers (in the range of some kg/h) obtained in the inventive method may be easily disposed by dilution and heating with prevention of plugging.
The features disclosed in the foregoing description, in the drawing or in the claims may, both separately and in any combination thereof, be material for realizing the invention in diverse forms thereof.

WE CLAIM:
1. Method for the preparation of linear alpha-olefins by oligomerization of ethylene in a reactor
in the presence of a solvent and a catalyst, characterized in that from a discharge stream of the
reactor comprising the solvent, catalyst, linear alpha-olefins and substantially high molecular
weight oligomers being substantially solid at reaction temperature, the high molecular weight
oligomers are separated in a separation unit and are then diluted with a dilution medium and
heated at 130°C to 200°C, whereupon the diluted high molecular weight oligomers are thcn
transferred to a disposal device, wherein a part of the diluted high molecular weight oligomers is
disposed and another part thereof is recycled in a loop downstream the separation unit, wherein
flow rates of the loop streams are from 1 to 50 m3/h.
2. Method as claimed in claim I , wherein the high molecular weight oligomers arc separated in a
filter unit or a distillation unit.
3. Method as claimed in claim 1, wherein the temperature in the reactor is from 60 to 1 OO°C.
4. Method as claimed in any of the preceding claims, wherein the solvent is toluene.
5. Method as claimed in any of the preceding claims, wherein the dilution medium is toluene
and/or a liquid fraction of the oligomerization product comprising oligomers having Inore than
18 carbon atoms.
6. Method as claimed in any of the preceding claims, wherein the dilution lnediurn comprises the
bottom product ofa purification apparatus, preferably a distillation column, for the solvent.
7. Method as claimed in any of the preceding claims, wherein the dilution medium with
dissolved high molecular weight oligomers is recycled in a loop.
8. Method as claimed in any of the preceding claims, wherein the disposal device is an
incinerator.
9.Mcthod as claimed in any of the preceding claims, wherein the dilution ratio of the dilution
medium: high molecular weight oligomer is 5: 1 to 15: 1, preferably 10: 1.

Documents:

10226-delnp-2007-Abstract-(24-06-2013).pdf

10226-delnp-2007-abstract.pdf

10226-delnp-2007-Claims-(14-02-2014).pdf

10226-delnp-2007-claims.pdf

10226-delnp-2007-Correspondence Others-(14-02-2014).pdf

10226-delnp-2007-Correspondence-Others-(11-02-2009).pdf

10226-delnp-2007-Correspondence-Others-(24-06-2013).pdf

10226-delnp-2007-correspondence-others.pdf

10226-delnp-2007-description(complete).pdf

10226-delnp-2007-drawings.pdf

10226-delnp-2007-Form-1-(11-02-2009).pdf

10226-delnp-2007-form-1.pdf

10226-delnp-2007-Form-18-(11-02-2009).pdf

10226-delnp-2007-form-2.pdf

10226-delnp-2007-Form-3-(24-06-2013).pdf

10226-delnp-2007-form-3.pdf

10226-delnp-2007-Form-5-(24-06-2013).pdf

10226-delnp-2007-form-5.pdf

10226-delnp-2007-GPA-(11-02-2009).pdf

10226-delnp-2007-pct-210.pdf

10226-delnp-2007-pct-220.pdf

10226-delnp-2007-pct-237.pdf

10226-delnp-2007-pct-304.pdf

10226-delnp-2007-pct-306.pdf

10226-delnp-2007-Petition-137-(24-06-2013).pdf

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Patent Number

258990

Indian Patent Application Number

10226/DELNP/2007

PG Journal Number

08/2014

Publication Date

21-Feb-2014

Grant Date

19-Feb-2014

Date of Filing

31-Dec-2007

Name of Patentee

LINDE AG

Applicant Address

LEOPOLDSTR. 252, 80807 MUNICH, GERMANY

Inventors:

#	Inventor's Name	Inventor's Address
1	HEINZ BOLT	KANAISTR. 21, 82515 WOLFRATSHAUSEN, GERMANY
2	SULTAN AL-OTAIBI	SAUDI BASIC INDUSTRIES CORPORATION,P.O.BOX 5101, 11422 RIYADH, SAUDI ARABIA
3	PETER FRITZ	TRUDERINGER STRASSE 21, 82008 UNTERHACHING, GERMANY
4	STEFAN GLANZ	ERLENSTRASSE 6, 85579 NEUBIBERG, GERMANY
5	RICHARD SCHNEIDER	AUF DER HADERN 1, 82449 UFFING, GERMANY
6	TALAL ALI	SAUDI BASIC INDUSTRIES CORPORATION,P.O.BOX 5101, 11422 RIYADH, SAUDI ARABIA
7	FUAD MOSA	SAUDI BASIC INDUSTRIES CORPORATION,P.O.BOX 5101, 11422 RIYADH, SAUDI ARABIA

PCT International Classification Number

C07C 2/34

PCT International Application Number

PCT/EP2006/005641

PCT International Filing date

2006-06-13

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	05016524.0	2005-07-29	EPO