Title of Invention

A CATALYST ACTIVATOR VESSEL FOR HEAT CONDITIONING A CATALYST

Abstract A catalyst activator vessel for heat conditioning a catalyst is disclosed. The activator vessel includes inner and outer vessels, a perforated, normally generally horizontal grid plate within the inner vessel, and a fluid path extending through the grid plate within the vessel. The inner vessel can have an inside diameter of at least 50 inches (1.27 m). The space between the inner and outer vessels defines a flue. The perforated grid plate within the inner vessel can have an upper surface perforated with a pattern of overlapping, generally conical depressions and a lower surface, optionally overlapping by at least 17%. The fluid path extends upwardly through the perforated grid plate and is a conduit along which a fluid flows through the grid plate. The fluid will fiuidize a particulate material, such as a catalyst, disposed above the grid plate in the inner vessel.
Full Text

LARGE CATALYST ACTIVATOR
BACKGROUND OF THE INVENTION
The invention relates generally to a catalyst activator for heating the catalyst
and conditioning it with a gas. The invention relates more particularly to a catalyst activator
for conditioning olefin polymerization catalysts.
Many solid catalyst compositions, such as those employed in hydrocarbon
conversion operations, e.g., polymerization, cracking, dehydrogenation, hydrogenation, and
the like, are activated by subjecting the raw catalyst to elevated temperatures for an interval
of time, while passing over the catalyst a stream of conditioning fluid which is inert, non-
oxidizing, non-reducing, oxidizing, reducing, dry, or the like, depending on the particular
nature of the catalyst and its intended use. One of the common objects of such treatment is
the removal of moisture from the catalyst, since water is a catalyst poison in many
applications.
Catalyst activation processes comprise drying an activating fluid such as air
and passing it through a catalyst bed at a constant rate, while applying heat, until the catalyst
reaches the desired temperature, at which point the catalyst is held at the activation
temperature for the proper length of time. However, solid catalyst compositions are often
relatively impermeable, thus requiring a shallow bed in order to obtain the required flow of
activating fluid. The bed thus becomes large and expensive.
To alleviate the deficiencies encountered in activating solid particulate
catalysts, including the continuous removal of impurities and catalyst poisons from the
activation zones and temperature control of the bed, fluidized activation processes have been
developed. In these processes, the catalyst is fluidized with a stream of activating fluid at
elevated temperatures.
One type of fluidized bed catalyst activator has a grid plate through which
fluidizing gas flows upwardly to levitate particulate matter, forming the fluidized bed. The
upper surface of the grid plate is machined with an array of generally conical depressions that
overlap essentially completely so the upper surface of the grid plate has no flat surfaces on
which catalyst particles can accumulate and escape the conditioning effect of the fluidizing
gas.
In one known catalyst activator the grid plate (see Figure 1) is nominally 1.13
inch (28.58 mm) thick (dimension a, Figure 1), has an inside diameter of 42 inches (1,07 m),

and the generally conical depressions are predominantly 90-degree (angle b, Figure 1) conical
depressions having a nominal depth of one inch (25.4 mm) (dimensions a-c), a nominal
diameter d at the upper major surface of 2.078 inches (52.78 mm), spaced apart in each
direction by 1.781 inches (45.2 mm) from center to center, thus overlapping by about 16.7%.
The nominal layout of a single 90-degree conical depression of the 42-inch
(1.07 m) grid plate is shown in Figure 1. This known grid plate has 418 90-degree conical
depressions, and around the outside periphery, where there is less clearance allowed to drill
depressions, the grid plate has eighteen 70.5-degree conical depressions and twelve 60-degree
conical depressions, for a total of 448 conical depressions of the three sizes provided. The
depth of each type of conical depression is the same. The apex of each conical depression
was bored through to the lower surface of the grid plate by drilling a 0.078 inch (1.98 mm)
diameter (dimension e), 0.125 inch (3.175 mm) deep (dimension c) bore.
As polymerization reactors have increased in size or number at a given plant
location, the amount of catalyst needed has increased, and a need has arisen to increase the
amount of catalyst activated at a given time.
One approach to this problem is to provide more than one catalyst activator.
This approach has the problem of requiring more equipment, operating personnel and other
resources, including the vessels, sensors, piping, wiring, and computer capacity, than one
catalyst activator.
Another approach to this problem is to operate a catalyst activator of the same
diameter as before, but with a deeper fluidized bed of catalyst. A problem created by this
approach is that a deeper fluidized bed allows less activation air and more activation effluent
from the fluidized bed to contact each particle of the catalyst, which may reduce the quality
of the resulting activated catalyst.
Yet another approach, increasing the diameter of the activator, has previously
been rejected for at least two reasons.
First, increasing the diameter of the inner vessel reduces its surface area
exposed to flue gases, as a proportion of the interior volume. As the diameter increases, the
wall surface area of the inner vessel increases proportionally to the increase in diameter,
while the volume of the inner vessel (assuming the depth of the vessel remains constant)
increases proportionally to the square of the increase in diameter. Also, the heat must be
transferred further to reach the center of a larger-diameter vessel. These effects reduce the
amount of heat transferred per unit volume, per unit time, and per particle of the catalyst in
the inner vessel.
Second, increasing the diameter of the grid plate that establishes a fluidized
bed, and the size of the catalyst charge the grid plate is required to support, increases the
weight of the grid plate, the diameter the grid plate must span, and the weight of catalyst the

grid plate must bear. Simply scaling up the grid plate dimensions would require the grid
plate to be quite thick to support both its own weight and that of a larger catalyst charge over
a greater span. The depressions milled into the surface of the grid plate to eliminate flat areas
further exacerbate this problem, as a considerable amount of metal is removed to form the
depressions, thus effectively decreasing the thickness of the grid plate.
Thus, simply scaling up the catalyst activator is not a satisfactory solution to
the problem of processing more catalyst per batch.
SUMMARY OF THE INVENTION
One aspect of the invention is a catalyst activator vessel for heat conditioning
a catalyst. The activator vessel includes inner and outer vessels, a perforated, normally
generally horizontal grid plate within the inner vessel, and a fluid path extending through the
grid plate within the vessel.
The inner vessel can enclose a catalyst charge. The outer vessel generally
surrounds the inner vessel. The space between the inner and outer vessels defines a flue.
The perforated grid plate within the inner vessel has an upper surface and a
lower surface. The upper surface has a pattern of generally conical depressions that overlap
by at least 17%. The grid plate is perforated by holes extending from the generally conical
depressions through its lower surface. The fluid path extends upwardly through the
perforated grid plate and is defined by a conduit along which fluidizing gas flows through the
grid plate. The fluidizing gas will fluidize a particulate material, such as a catalyst, disposed
above the grid plate in the inner vessel.
Another aspect of the invention is a catalyst activator vessel for heat
conditioning a catalyst, in which the inner vessel has an inside diameter of at least 50 inches
(1.27 m), the grid plate is more broadly defined as a normally generally horizontal, perforated
grid plate disposed in the inner vessel, and other features are as described in the first aspect of
the invention.
Another aspect of the invention is a fluidization bed comprising a vessel, a
normally generally horizontal, perforated grid plate disposed in the vessel, and a fluid path
extending upwardly through the grid plate. The grid plate and fluid path are defined above.
Another aspect of the invention is a perforated grid plate having an upper
major surface perforated with a pattern of generally conical depressions and an opposed
lower major surface, wherein the generally conical depressions overlap by at least 17%.
DEFINITIONS
As used in this specification:

"Generally," "normally," or "substantially," as in the phrases "generally
horizontal," "an outer vessel generally surrounding said inner vessel," "generally conical
depressions," generally cone-shaped," "generally funnel-shaped," "generally cylindrical
portions," "normally disposed below the level of said outer margin," "substantially at said
apex," and any others, is broadening language intending to embrace both a feature that is
shaped, oriented, or located either exactly or approximately, and either fully or partially, as
described in the balance of the phrase.
For example, a "generally horizontal" grid plate as defined in this
specification can have a portion that is not horizontal - such as its outer flange. The entire
plate can be not exactly horizontal, as it may have a concavity of 5 degrees or more below a
horizontal plane, or it can be tilted somewhat out of a true horizontal orientation when in use,
and still is regarded as "generally horizontal" herein. When a "generally horizontal" structure
as defined here is not in use, it may be disposed in any orientation, even vertical, and still be
"generally horizontal" as defined herein, providing it would be at least nearly horizontal
when in normal use.
"Upper" and "lower" are defined with respect to a normal orientation of an
article or part when used as contemplated in this specification.
"Overlapping," as in "overlapping, generally conical depressions," indicates
two structures or surfaces that intersect in a finite region, so each structure or surface is
interrupted by the other. "Completely overlapping" means that the overlap extends in an
unbroken circle all the way around the conical depression in question, while "partially
overlapping" is indicative that the overlap does not extend in an unbroken circle, but is
broken at least at one point about the circumference of the depression. Percentage overlap
refers to the amount, expressed as a percentage, by which the nominal diameter of a
depression exceeds the center-to-center spacing between the depression and the nearest
adjacent depression. A representative calculation of percentage overlap is provided in this
specification.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a fragmentary sectional view, taken similarly to Figure 5, of a prior
art grid plate, showing the nominal dimensions of a generally funnel-shaped 90-degree
conical depression.
Figure 2 is a schematic longitudinal section of a catalyst activator according to
the present invention.
Figure 3 is a fragmentary plan view of the grid plate of the catalyst activator of
Figure 2, showing the layout of the conical depressions.
Figure 4 is a section taken along section line 4—4 of Figure 3.

Figure 5 is a fragmentary sectional view of a 90-degree conical depression,
taken along section line 5—5 of Figure 3.
Figure 6 is a fragmentary sectional view of a 70.5-degree conical depression,
taken along section line 6—6 of Figure 3.
Figure 7 is a fragmentary perspective view of the upper major surface of the
grid plate of Figure 3.
DETAILED DESCRIPTION OF THE INVENTION
While the invention will be described in connection with one or more aspects,
it will be understood that the invention is not limited to those aspects. On the contrary, the
invention includes all alternatives, modifications, and equivalents as may be included within
the spirit and scope of the appended claims.
Figure 1 represents the prior art, and is discussed in connection with Figure 5
below.
Figure 2 shows a catalyst activator 10 according to the present invention for
heat conditioning a catalyst. The illustrated activator 10 includes an inner vessel 12, an outer
vessel 14 generally (here, partially) surrounding the inner vessel 12, a perforated grid plate
16, and a fluid path 18 defined in part by the perforations in the grid plate 16. These
perforations are illustrated in the remaining Figures.
The activator 10 of this aspect of the invention further includes a furnace 20
having a gas burner 22 and an air supply 24 supplying combustion air. The furnace 20 has a
flue 26 communicating with the outer vessel 14 and a smoke stack 28 also communicating
with the outer vessel 14 to take away the exhaust from the furnace 20. Thus, the space
between the inner and outer vessels 12 and 14 defines part of the flue that exchanges heat
with the inner vessel 12 to heat the catalyst charge 30 when the charge is within the inner
vessel 12. Any source of heat, such as electrical resistance heating, high temperature fluid, or
high pressure steam, can also or instead be used to heat the activator 10. The specific heating
arrangement employed here is not critical to the practice of the invention.
One surprising feature of the present invention is that the inner vessel 12 can
be scaled up from a nominal 42-inch (1.07 m) inner diameter to a nominal 60-inch (1.52 m)
inner diameter, thus approximately doubling the area of the grid plate 16 while increasing the
surface area of the inner vessel 12 by less than 50%, and thus decreasing the surface area of
the inner vessel 12 per unit volume within the inner vessel 12, without substantially reducing
the rate at which the contents of the inner vessel can be heated to the very high temperature
(800°F to 1700°F, 427°C to 927°C) required for activation. The same rate of temperature
increase achieved in the 42-inch (1.07 m) vessel can be achieved in the 60-inch (1.52 m)
vessel by raising the flue gas temperature only a small amount.

While the inventor does not wish to be bound by the accuracy of the following
theory, he theorizes that the heat transfer rate into the inner vessel 12 is unexpectedly-;high
because much of the heat is transferred in the form of radiant heat, which transfers at a rate
proportional to the fourth power of the temperature difference of the objects between which
the heat transfer occurs. In other words, when the catalyst charge is relatively cool compared
to the temperature of the flue gas, the rate of heat transfer to the catalyst charge is extremely
high, so it quickly approaches the intended temperature. Also, a relatively small increase in
the flue gas temperature causes a relatively large increase in the rate of radiant heat transfer,
compared to the corresponding increase in convective or conductive heat transfer:
The activator 10 has a source 32 of a fluidizing medium, which in this aspect
of the invention is nitrogen gas, although other gases, such as dry air, or potentially liquids
may find use as a fluidizing medium, depending on the conditions required to activate the
catalyst charge 30. The fluidizing medium 32 is introduced via the fluid path 18 upward
through the grid plate 16 into the catalyst charge 30, with sufficient fluid velocity and under
other conditions suitable to fluidize the catalyst charge 30. The fluidizing medium 32 also
contacts the catalyst particles and optionally conditions them. For example, to remove
moisture from the catalyst charge, the fluidizing medium 32 may be a dry preheated gas that
will entrain or allow evaporation of moisture.
The fluidizing medium 32 and any effluent from the catalyst charge 30, such
as fines and moisture, flows upward within the inner vessel 12 from the catalyst charge 30 to
effluent treatment apparatus generally indicated as 34 of this aspect of the invention, which
takes moisture and other effluents out of the fluidizing medium 32, and returns most of the
fines to the catalyst charge 30.
In this aspect of the invention, the catalyst charge 30 to be conditioned is
introduced from a catalyst supply 36 via a catalyst introduction conduit 38. In this aspect of
the invention, the catalyst charge 30 is introduced into the inner vessel 12 by conveying it on
a stream of inert fluid, such as nitrogen gas.
In this aspect of the invention, the conditioned catalyst charge 30 is removed
from the inner vessel 12 via a drain 40 which extends from a drain hole 42 at the center of the
grid plate. When the catalyst charge 30 is being conditioned, a cap 44 is set in the drain hole
42, blocking it. To remove the catalyst charge 30, the cap 44 is raised out of the drain hole
42 by elevating a plunger 46 connected by a plunger rod 48 to the cap 44. The fluidized bed
will then drain through the drain 40 into a suitable vessel, such as the tote bin 50 shown in
Figure 2. Instead of discharging the catalyst charge 30 to the tote bin 50, the catalyst charge
could alternatively be discharged directly to a reactor requiring the catalyst, although the
illustrated arrangement is desirable for a direct fired activator, so the activator will not be a
source of ignition for any release of hydrocarbon from the polymerization reactor equipment.

Figures 3-7 show different parts of the grid plate 16 of the catalyst activator of
Figure 2. Figure 3 shows one quarter of the grid plate 16. Referring now especially to Figure
4, the grid plate 16 is normally generally horizontal, having an upper major surface 52
perforated with an array of generally conical depressions such as 54 and 56 (the depressions
56 are shown only in Figure 3), a lower major surface 58, an outer flange 60 defining an outer
margin 62, and a concave or lower center 64 normally disposed below the level of the outer
margin 62. An "array" as used here is defined to include a patterned array or a randomized
array. One example of a patterned array is a triangular array, more particularly an equilateral
triangular array, as illustrated by this aspect of the invention. Another example of a suitable
patterned array is a square array. The array may have a regular pattern or a randomized
pattern. For any type of array, it may be desirable to ensure that no substantial amount of
land or horizontal surface area be provided between the depressions.
The words "concave" and "concavity" are used to define the position of the
center in relation to the outer margin, and are defined broadly so as to include upper major
surfaces that are either linear or curved.
In this aspect of the invention the concavity in the upper major surface 52 is
defined by an approximately 5.5° radial downward slope from the outer margin 62 to the
center 64. Therefore, the upper major surface 52 is generally cone-shaped, its outer margin
62 defining the base and its center 64 defining the apex of the cone. This slight concavity or
departure from an absolutely horizontal upper major surface 52 is provided so the grid plate
16 will drain when the charge 30 of catalyst is to be removed from the inner vessel 12.
The grid plate 16 has a drain aperture 42 located substantially at its apex or
center 64 for passing treated particulate material down through the grid plate.
The grid plate 16 upper major surface 52 has a nominal diameter of at least 43
inches (1.09 m), alternatively at least 44 inches (1.12 m), alternatively at least 45 inches (1.14
m), alternatively at least 46 inches (1.17 m), alternatively at least 47 inches (1.19 m),
alternatively at least 48 inches (1.22 m), alternatively at least 49 inches (1.24 m), alternatively
at least 50 inches (1.27 m), alternatively at least 51 inches (1.3 m), alternatively at least 52
inches (1.32 m), alternatively at least 53 inches (1.35 m), alternatively at least 54 inches (1.37
m), alternatively at least 55 inches (1.4 m), alternatively at least 56 inches (1.42 m),
alternatively at least 57 inches (1.45 m), alternatively at least 58 inches (1.47 m), alternatively
at least 59 inches (1.5 m), alternatively at least 60 inches (1.52 m) (as in the illustrated aspect
of the invention), alternatively at least 62 inches (1.57 m), alternatively at least 65 inches
(1.65 m), alternatively at least 70 inches (1.78 m), alternatively at least 75 inches (1.91 m),
alternatively at least 80 inches (2.03 m), alternatively at least 85 inches (2.16 m), alternatively
at least 90 inches (2.29 m), alternatively at least 95 inches (2.41 m), alternatively at least 100
inches (2.54 m), alternatively at least 105 inches (2.67 m), alternatively at least 110 inches

(2.79 m), alternatively at least 115 inches (2.92 m), alternatively at least 120 inches (3.05 m).
The diameter of the portion of the upper major surface 52 that is drilled with apertures is
about 58 inches (1.47 m) in this aspect of the invention.
Figures 3, 4, and 7 show the layout of the 90° conical depressions such as 54,
mostly shown as full hexagons in Figure 3 (except for the marginal 90° conical depressions
54, which have a partially circular outer periphery). The 70.5° conical depressions 56 fit into
the periphery where there is insufficient room for a 90° depression. The depressions 56 all
have partially hexagonal, partially circular outlines.
The conical depressions; 54,56 are laid out in an equilateral triangular array,
made up of a first family of equidistant parallel imaginary lines such as 66, crossed by a
second family of equidistant parallel imaginary lines such as 68. The lines of the second
family form angles of 60 degrees relative to the lines of the first family. The crossing points
of the imaginary lines 66 and 68 locate the centers of the generally conical depressions 54
and 56. Other patterns of conical depressions are also contemplated.
In this aspect of the invention, the pitch or spacing between the adjacent
parallel lines 66 or the adjacent parallel lines 68 is 1.5 inches (38.1 mm). This is closer
spacing than was used in the 42-inch (1.07 m) prior art activator discussed in the background
section, in which the pitch was 1-25/32 or 1.781 inches (45.2 mm). Alternatively, the pitch
can be 1.78 inches (45.2 mm), alternatively 1.77 inches (45.0 mm), alternatively 1.76 inches
(44.7 mm), alternatively 1.75 inches (44.5 mm), alternatively 1.74 inches (44.2 mm),
alternatively 1.73 inches (43.9 mm), alternatively 1.72 inches (43.7 mm), alternatively 1.71
inches (43.4 mm), alternatively 1.7 inches (43.2 mm), alternatively 1.69 inches (42.9 mm),
alternatively 1.68 inches (42.7 mm), alternatively 1.67 inches (42.4 mm), alternatively 1.66
inches (42.2 mm), alternatively 1.65 inches (41.9 mm), alternatively 1.64 inches (41.7 mm),
alternatively 1.63 inches (41.4 mm), alternatively 1.62 inches (41.1 mm), alternatively 1.61
inches (40.9 mm), alternatively 1.6 inches (40.6 mm), alternatively 1.59 inches (40.4 mm),
alternatively 1.58 inches (40.1 mm), alternatively 1.57 inches (39.9 mm), alternatively 1.56
inches (39.6 mm), alternatively 1.55 inches (39.4 mm), alternatively 1.54 inches (39.1 mm),
alternatively 1.53 inches (38.9 mm), alternatively 1.52 inches (38.6 mm), alternatively 1.51
inches (38.4 mm), alternatively 1.5 inches (38.1 mm), alternatively 1.49 inches (37.8 mm),
alternatively 1.48 inches (37.6 mm), alternatively 1.47 inches (37.3 mm), alternatively 1.46
inches (37.1 mm), alternatively 1.45 inches (36.8 mm), alternatively 1.44 inches (36.6 mm),
alternatively 1.43 inches (36.3 mm), alternatively 1.42 inches (36.1 mm), alternatively 1.41
inches (35.8 mm), alternatively 1.4 inches (35.6 mm), alternatively less than any of the
previously stated values. Still smaller alternative pitches are also contemplated. One family
of pitch lines may also be further apart than the other family of pitch lines, or the pitch lines

may be different distances apart in different areas of the surface, without departing from the
present invention.
In this aspect of the invention, the pitch was specified to obtain a desired
number of holes, and the number and diameter of holes was specified to give the desired total
required gas flow. The fluidization gas velocity through the holes was held the same as the .
rate previously used for a 42-inch catalyst activator so that particle attrition was not
increased. This was accomplished by making the increased number of holes per unit area of
grid proportionally smaller.
One advantage of reducing the pitch is that the depth of the conical depression
required to provide fully overlapping depressions is reduced, which means that more of the
thickness of the grid plate remains to support the weight of the grid plate and the catalyst.
Another advantage of reducing the pitch is to increase the number of holes among which the
flow is divided, so the distribution of the fluidizing medium is more uniform. Improved
uniformity in the fluidization medium, resulting from the shorter distances between adjacent
jets or sources of the fluidization medium, assures improved contact of the fluidization
medium with the catalyst. This improves the uniformity and quality of the catalyst.
Referring to Figure 5, the 90° conical depressions 54 as milled into the upper
major surface 52, without considering any of the overlapping depressions, are conical, and
have circular margins 70. The conical depressions of the 42-inch (1.07 m) prior art grid plate
(see Figure 1) were generally conical as well. The nominal diameters of the 90° conical
depressions of the 42-inch (1.07 m) prior art grid plate were 2.078 inches (52.78 mm). The
nominal diameters of the present 90° conical depressions can be 2.07 inches (52.6 mm),
alternatively 2.06 inches (52.3 mm), alternatively 2.05 inches (52.1 mm), alternatively 2.04
inches (51.8 mm), alternatively 2.03 inches (51.6 mm), alternatively 2.02 inches (51.3 mm),
alternatively 2.01 inches (51.1 mm), alternatively 2.00 inches (50.8 mm), alternatively 1.99
inches (50.5 mm), alternatively 1.98 inches (50.3 mm), alternatively 1.97 inches (50.0 mm),
alternatively 1.96 inches (49.8 mm), alternatively 1.95 inches (49.5 mm), alternatively 1.94
inches (49.3 mm), alternatively 1.93 inches (49.0 mm), alternatively 1.92 inches (48.8 mm),
alternatively 1.91 inches (48.5 mm), alternatively 1.9 inches (48.3 mm), alternatively 1.89
inches (48.0 mm), alternatively 1.88 inches (47.8 mm), alternatively 1.87 inches (47.5 mm),
alternatively 1.86 inches (47.2 mm), alternatively 1.85 inches (47.0 mm), alternatively 1.84
inches (46.7 mm), alternatively 1.83 inches (46.5 mm), alternatively 1.82 inches (46.3 mm),
alternatively 1.81 inches (46.0 mm), alternatively 1.8 inches (45.7 mm), alternatively 1.79
inches (45.5 mm), alternatively 1.78 inches (45.2 mm), alternatively 1.77 inches (45.0 mm),
alternatively 1.76 inches (44.7 mm), alternatively 1.75 inches (44.5 mm), alternatively 1.74
inches (44.2 mm), alternatively 1.73 inches (43.9 mm), alternatively 1.72 inches (43.7 mm),
alternatively 1.71 inches (43.4 mm), alternatively 1.7 inches (43.2 mm) in diameter,

alternatively less than any of the previously stated values. In the aspect of the invention
illustrated, the diameters of the conical depressions at the base are 1.813 inches (46.05 mm).
The depths of the generally conical depressions in the 42-inch (1.07 m) prior
art grid plate were uniformly one inch (25.4 mm), and the nominal thickness of the 42-inch
(1.07 m) prior art grid plate was 1.125 inches (28.6 mm), so the depth of the generally conical
depression was 89% of the nominal thickness of the plate. The depths of the generally
conical depressions in the illustrated aspect of the invention are 0.91 inch (23.1 mm), and the
nominal thickness of the grid plate is 1.625 inches (41.3 mm), so the depth of the conical
depressions is 56% of the nominal thickness of the plate. Alternatively, the ratio of
depression depth to nominal plate thickness can be 80%, 79%, 78%, 77%, 76%? 75%, 74%,
73%, 72%, 71%, 70%, 69%, 68%, 67%, 66%, 65%, 64%, 63%, 62%, 61%, 60%, 59%, 58%,
57%, 56%, 55%, 54%, 53%, 52%, 51%, 50%, or less.
As shown in Figure 3, the margins of the non-peripheral depressions 54 are
regular hexagons, in a plan view, because the generally conical depressions overlap
essentially completely; their nominal base diameters are greater than their pitch. Where two
adjacent conical depressions overlap, they intersect along a curved line 72 that is a segment
of a circle lying in a plane perpendicular to the|major surface 52. Viewed from above (Figure
3) or in section (Figure 4), the overlap appears as a straight line. Figure 7 shows that the
overlapping generally conical depressions 54 have six scallops defining their margins. This
configuration is illustrated as well in Figure 1, which shows the scalloped edges out of the
plane of the section.
In the 42-inch (1.07 m) prior art grid plate, the pitch was 1.781 inches (45.2
mm), and the nominal base diameters of the generally conical depressions were 2.078 inches
(52.78 mm), so the degree of overlap was:
((2.078 /1.781)- 1) x 100% = 16.7%.
In one aspect of the present grid plate 16, the pitch is 1.5 inches (38.1 mm), and the nominal
base diameters of the generally conical depressions 54 are 1.813 inches (46.05 mm), so the
overlap is 20.86%. Alternative degrees of overlap contemplated here are 17%, 17.1%,
17.2%, 17.3%, 17.4%, 17.5%, 17.6%, 17.7%, 17.8%, 17.9%, 18%, 18.1%, 18.2%, 18.3%,
18.4%, 18.5%, 18.6%, 18.7%, 18.8%, 18.9%, 19%, 19.1%, 19.2%, 19.3%, 19.4%, 19.5%,
19.6%, 19.7%, 19.8%, 19.9%, 20%, 20.1%, 20.2%, 20.3%, 20.4%, 20.5%, 20.6%, 20.7%,
20.8%, 20.9%, 21%, 21.1%, 21.2%, 21.3%, 21.4%, 21.5%, 21.6%, 21.7%, 21.8%, 21.9%,
22%>, or more.
Another way of viewing the distinction between the present invention and the
prior art is that, in the present invention, the generally conical depressions are shallower, as a
proportion of the thickness of the grid plate, but more overlapped, so there are more
perforations per square inch or mm of the grid plate surface.

Comparing Figures 1 and 5, another difference between the present grid plate
of Figure 5 and the prior art grid plate of Figure 1 is the configuration of the perforations 74
of the present invention, versus the perforations 76 of the prior art. The prior art perforation
76 is a simple bore having a diameter of 0.078 inch (1.98 mm) and a length of 1/8 inch (3.18
mm), drilled in the apex of the generally conical depression.
The perforation 74 of the present invention is a compound bore having an
upper portion or neck or second generally cylindrical portion 78 and a lower or first generally
cylindrical portion 80. The portion 78 communicates with the conical depression and has a
diameter of 0.063 inch (1.59 mm), or less than 0.078 inch (1.98 mm), and a length of 1/8 inch
(3.18 mm). Alternatively, the portion 78 can have a smaller diameter, such as 1/32= inch
(0.031 inches, 0.79 mm). The portion 80 has a diameter of 0.25 inch (6.35 mm) and a depth
of about 0.4 inch (10 mm), including a tapered back wall. Since the perforation 74 of the
present invention is much longer than the perforation 76 of the prior art, and has a smaller
diameter, it is more easily drilled by drilling the smaller-diameter part of the compound bore
from above, and drilling the larger-diameter part of the compound bore from below. Since
the very small diameter part of the bore is short, the very small drill bit is much less likely to
shear off when the bores are being drilled.
The present invention can be distinguished from the prior art by the number of
perforations in the grid plate 16. If the prior art 42-inch (1.07 m) grid plate (which has a field
of holes 20 inches (508 mm) in radius, and 448 perforations), were simply scaled up to 60
inches (1.52.m) (with a field of holes 29 inches (737 mm) in radius) with the same pitch, it
would have approximately:
448 (29 / 20)2 = 941 perforations
The present 60-inch (1.52 m) grid plate has 1338 perforations, which is about 397 more than
the number of perforations it would have if it were merely scaled up. Alternatively, the
present 60-inch (1.52 m) grid plate has at least 1000, alternatively at least 1050, alternatively
at least 1100, alternatively at least 1150, alternatively at least 1200, alternatively at least
1250, alternatively at least 1300, alternatively at least 1350, alternatively at least 1400,
alternatively at least 1450, alternatively at least 1500, alternatively at least 1550, alternatively
at least 1600, alternatively at least 1650, alternatively at least 1700, alternatively at least
1750, alternatively at least 1800, alternatively at least 1850, alternatively at least 1900,
alternatively at least 1950, alternatively at least 2000, alternatively at least 2100, alternatively
at least 2200, alternatively at least 2300, alternatively at least 2400, alternatively at least
2500, alternatively at least 2600, alternatively at least 2700, alternatively at least 2800,
alternatively at least 2900, alternatively at least 3000, alternatively at least 3100, alternatively
at least 3200, alternatively at least 3300, alternatively at least 3400, alternatively at least
3500, alternatively at least 3600, alternatively at least 3700, alternatively at least 3800,

alternatively at least 3900, alternatively at least 4000, alternatively at least 4500, alternatively
at least 5000, alternatively at least 5500, alternatively 6000 or more overlapping, generally
conical depressions or perforations.
The present invention can further be distinguished from the prior art by the
number of perforations in the grid plate 16, per square inch (cm2) of the perforated plate
radius. The prior art 42-inch (1.07 m) grid plate has a surface area of 3.14159 (20)2 = 1257

in2 (8110 cm2 ) and 448 perforations, or 0.356 perforations per square inch (2.30 per cm ).
The illustrated 60-inch (1.52 m) grid plate has a perforated surface area of-3.14159 (29)2 =
2642 in and 1338 perforations, or 0.506 perforations per square inch (3.26 per cm2).
Alternative numbers of perforations per square inch contemplated herein are,-0.36 per in2
(2.32 per cm2), 0.37 per in2 (2.39 per cm2), 0.38 per in2 (2.45 per cm2), 0.39;per»in2 (2.52 per
cm2), 0.4 per in2 (2.58 per cm2), 0.41 per in2 (2.65 per cm2), 0.42 per in2 (2.71 per cm2), 0.43
per in2 (2.77 per cm2), 0.44 per in2 (2.84 per cm2), 0.45 per in2 (2.90 per cm2), 0.46 per in2
(2.97 per cm2), 0.47 per in2 (3.03 per cm2), 0.48 per in2 (3.097 per cm2), 0.49 per in2 (3.16 per
cm2), 0.5 per in2 (3.23 per cm2), 0.51 per in2 (3.29 per cm ), 0.52 per in2 (3.35 per cm2), 0.53
per in2 (3.42 per cm2), 0.54 per in2 (3.48 per cm2), 0.55 per in2 (3.55 per cm2), 0.56 per in2
(3.61 per cm2), 0.57 per in2 (3.68 per cm2), 0.58 per in2 (3.74 per cm2), 0.59 per in2 (3.81 per
cm ), or 0.6 per in (3.87 per cm2).
In the illustrated aspects of the invention, a multiplicity of the generally
conical depressions overlap six other contiguous generally conical depressions. This is true
of all the non-peripheral generally conical depressions, in the illustrated aspect of the
invention. Further, a multiplicity of the overlapping, generally conical depressions overlap
less than six other contiguous generally conical depressions, in the illustrated aspect of the
invention. This is true of the peripheral generally conical depressions.
The number of perforations in the grid plate 16 per unit area is greater, but the
diameter of the neck of each perforation, which limits the flow velocity, is less, than in the
prior art. By providing more closely spaced, smaller diameter holes, the overall air flow is
kept about the same, but is more finely distributed across more holes, which improves the
quality of fluidization and reduces the maximum airflow velocity at any one point (in
particular, directly in front of the hole). This change is contemplated to reduce catalyst
particle attrition and to improve the contact efficiency between the catalyst and the
fluidization air because of the reduced distances between adjacent holes.
The grid plate 16 can be made of any suitable material that will withstand the
conditions of activation. One example, of a suitable material is an INCONEL® 601 nickel-
chromium-aluminum alloy forging. If fabricated as indicated herein, the grid plate 16 will
support a catalyst load of at least 1500 lb (680 kg).

Other suitable materials suitable for use as porous substrates are sintered
materials which retain their structural integrity at activation temperature, which have a pore
size such that the substrate will not blind with catalyst fines, and which are resistant to
oxidation at operating conditions which would result in a reduction in permeability.
Representative of such materials are type 316 stainless steel, INCONEL® alloys or
HASTELLOY® alloys. Generally, the porous substrates can be formed from high melting
alloys of nickel, iron, and at least one other metal selected from the following group:
chromium, molybdenum, silicon, copper, and aluminum with alloys of nickel, iron, and
chromium being specifically contemplated.
The process of the present invention can be readily applied to the activation of
any solid particulate material, regardless of type and regardless of the activating fluid. More
particularly, the present invention is suited for the activation of particulate, metal oxide
catalytic materials, especially such catalytic materials as are employed in polymerization
reactions.
Catalytic materials which are especially advantageously activated in
accordance with this invention are supported monoolefin polymerization catalysts comprising
chromium, at least a portion of which is in the hexavalent form such as chromium trioxide.
These chromium-containing catalysts and their use as polymerization, particularly
monoolefin polymerization, catalysts are well known. A representative method of preparing
such catalysts is disclosed in U.S. Pat. No. 2,825,721, the disclosure of which is incorporated
here by reference. As set forth in that patent, the supported chromium oxide catalysts can be
prepared by depositing chromium oxide (e.g., Cr2O3) or a chromium compound calculable to
chromium oxide, on a suitable support and activating to leave part of the chromium on the
support in the hexavalent form. The support can be selected from one or more of the
following members: silica, alumina, thoria, zirconia, silica-alumina, silica-thoria, silica-
zirconia, acid-treated clays, and other materials generally known in the art as catalyst
supports. One suitable catalyst is a silica gel-supported chromium oxide.
As previously noted, the solid particulate catalysts are activated in accordance
with the present invention by heating the particulate catalyst at a suitable activation
temperature for a specified period of time. After such activation, the catalyst is cooled,
purged with an inert gas, and collected in a dry container. The activation can be
accomplished, for example, by heating the bed or deposit of catalyst at a temperature in the
range of about 400°F (204°C) to about 2000°F. (1090°C), alternatively about 800°F (about
427°) to about 1800°F. (about 982°C), for about 60 minutes to about 20 hours, alternatively
about 4 hours to about 12 hours. This activation at elevated temperatures can be done in
several stages such as gradually heating the bed of catalyst particles to an intermediate
temperature of approximately 400°F to about 800°F. (204°C to about 427°C) and holding the

particles at that temperature for 30 minutes to 2 hours after which a higher temperature, e.g.,
1400°F. (760°C), is employed.
Catalysts activated in accordance with the present invention are extremely
valuable in the polymerization and copolymerization of polymerizable olefins, especially
aliphatic and cyclic olefins including both mono- and diolefins, for example, ethylene,
butadiene, and the like.
To further illustrate the invention, a catalyst can be prepared by impregnating
a coprecipitated gel composite containing 90 weight percent silica and 10 weight percent
alumina with an aqueous solution of chromium nitrate. The total chromium trioxide content
of the catalyst is 2.5 weight percent. The composite is activated with the present apparatus at
a temperature of 1650°F (899°C) for 12 hours, using a superficial air velocity of 0.1 fps (3
cm/sec). The conditioned catalyst thus made is suitable for the polymerization of ethylene to
produce polyethylene. The chromium content is essentially intact, while the adsorbed water is
completely removed. The catalyst loss is minimal, i.e., virtually all catalyst charged to
activator is recovered in an activated condition, in comparison to standard activation
treatments wherein catalyst loss can approach values considerably in excess of 50 percent and
are as high as 65 percent.

WE CLAIM
1. A catalyst activator vessel (10) for heat conditioning a catalyst, comprising:
A. an inner vessel (12) for containing a catalyst (30);
B. an outer vessel (14) generally surrounding said inner vessel (12);
C. a flue (26) defined by the space between said inner and outer vessels;
D. a normally generally horizontal grid plate (16) disposed in said inner
vessel (12) said grid plate (16) having an upper major surface (52) a
lower major surface (58) and a nominal plate thickness between the
upper and lower major surfaces;
E. an array of generally conical depressions (54, 56) in said upper major
surface (52) that overlap by at least 17% and have a depression depth of
80% or less of the nominal plate thickness;
F. holes (74) perforating said grid plate (16) said holes (74) extending from
at least some of said generally conical depressions (54, 56) through said
lower surface (58) and
G. a fluid path (18) extending upwardly through said holes (74) and adapted
to pass a fluid through said grid plate (16) for fluidizing a particular
material disposed above said grid plate (16) in said inner vessel (12).
2. The catalyst activator vessel (10) of claim 1, wherein said generally conical
depressions (54) (56) have apices and at least some of said generally conical
depressions (54, 56) and holes (74) are generally funnel-shaped.
3. The catalyst activator vessel (10) of claim 2, wherein at least some of said holes
(74) are defined by the walls of bores having first generally cylindrical portions
(80) perforating said lower major surface (58) and intersecting, smaller
diameter, second generally cylindrical portions (78) perforating the apices of said
generally conical depressions (54, 56).

4. The catalyst, activator vessel (10) of claim 3, wherein said second generally
cylindrical portions 78 have diameters of 0.0625 inch (1.5 mm).
5. The catalyst activator vessel (10) of claim 3, wherein said second generally
cylindrical portions (78) have diameter of 0.078 inch (1.98 mm).
6. The catalyst activator vessel (10) of claim 1, wherein said upper major surface
(52) has an outer margin (62) and a concave center 64 normally disposed below
the level of said outer margin (62).
7. The catalyst activator vessel (10) of claim 6, wherein said upper major surface
(52) is generally cone-shaped, said outer margin (62) defining the base and said
center (64) defining the apex of the cone.
8. The catalyst activator vessel (10) of claim 7, further comprising a drain hole (42)
located substantially at said apex for passing treated particulate material down
through said plate (16).
9. The catalyst activator vessel (10) of claim 1, wherein said grid plate upper major
surface (52) has a nominal diameter of at least 50 inches (1.27 m).
10. The catalyst activator vessel (10) of claim 1, wherein said grid plate upper major
surface (52) has a nominal diameter of at least 58 inches (1.47 m).
11. The catalyst activator vessel (10) of claim 1, wherein said grid plate upper major
surface (52) has a nominal diameter of at least 120 inches (3.048 m).
12. The catalyst activator vessel (10) of claim 1, wherein said grid plate upper major
surface (52) has at least 1000 overlapping, generally conical depressions (54,
56).

13. The catalyst activator vessel (10) of claim 1, wherein said grid plate upper major
surface (52) has at least 1100 overlapping, generally conical depressions (54,
56).
14. The catalyst activator vessel (10) of claim 1, wherein said grid plate upper major
surface (52) has at least 1300 overlapping, generally conical depressions (54,
56).
15. The catalyst activator vessel (10) of claim 1, wherein said grid plate upper major
surface (52) has at least 6000 overlapping, generally conical depressions (54,
56).
16. The catalyst activator vessel (10) of claim 1, wherein said grid plate upper major
surface (52) has on average at least 0.40 overlapping, generally conical
depressions (54, 56) per square inch (2.58 per cm2) of said upper major surface
(52).
17. The catalyst activator vessel (10) of claim 16, wherein said grid plate upper
major surface (52) has on average at least 0.45 overlapping, generally conical
depression (54, 56) per square inch (2.9 per cm2) of said upper major surface
(52).
18. The catalyst activator vessel (10) of claim 1, wherein a multiplicity of said
overlapping generally conical depressions (54, 56) completely overlap at least
three other contiguous generally conical depressions (54, 56).
19. The catalyst activator vessel (10) of claim 1, wherein a multiplicity of said
overlapping, generally conical depressions (54, 56) overlap other contiguous
generally conical depressions (54, 56).

20. The catalyst activator vessel (10) of claim 1, wherein said grid plate (16) is made
of a nickel chromium-aluminium alloy forging, has a nominal thickness of 1 5/8
inches (41.3 mm), said upper major surface (52) has a diameter of at least 58
inches (1.47 m), and said grid plate (16) will support a catalyst load of at least
1500 lb (680 kg).
21. A catalyst activator vessel (10) for heat conditioning a catalyst, comprising:
A. an inner vessel (12) having an inside diameter of at least 50 inches (1.27
m) for containing a catalyst charge (30);
B. an outer vessel (14) generally surrounding said inner vessel (12);
C. a fuel (26) defined by the space between the inner and outer vessels;
D. a normally generally horizontal, perforated grid plate 16 disposed in said
inner vessel (12); and
E. a fluid path (18) extending upwardly through said grid plate (16) and
adapted to pass a fluid through said grid plate (16) for fluidizing
particulate material disposed above said grid plate (16) in said inner
vessel (12).
22. A fluidization bed comprising:
A. a vessel comprising, an inner vessel (12) and an outer vessel (14)
generally surrounding said inner vessel (12);
B. a normally generally horizontal, perforated grid plate (16) disposed in
said inner vessel (12), said grid plate (16) having an upper major surface
(52) and a lower major surface (58);
C. an array of generally conical depressions (54, 56) in said upper surface
(52) that overlap by at least 17%, said grid plate (16) being perforated
by holes (74) extending from at least some of said generally conical
depressions (54, 56) through said lower surface (58); and
D. a fluid path (18) extending upwardly through said grid plate 16 and
adapted to pass a fluid through said grid plate (16) for fluidizing
particulate material disposed above said grid plate 16 in said inner vessel
(12).

23. A perforated grid plate (16) comprising:
A. an upper major surface (52) having an array of generally conical
depressions (54, 56) with a depression depth;
B. a lower major surface (58);
C. a nominal plate thickness between the upper major surface 52 and the
lower major surface (58); and
D. holes (74) extending from at least some of the generally conical
depressions (54, 56) through the lower surface (58) to form perforations
on the grid plate (16);
wherein the generally conical depressions (54, 56) overlap by at least
17%, and wherein said depression depth of said generally conical
depressions (54, 56) is 80% or less of the nominal plate thickness.



ABSTRACT OF THE DISCLOSURE


A CATALYST ACTIVATOR VESSEL FOR HEAT CONDITIONING A CATALYST.
A catalyst activator vessel for heat conditioning a catalyst is disclosed.
The activator vessel includes inner and outer vessels, a perforated, normally generally
horizontal grid plate within the inner vessel, and a fluid path extending through the grid
plate within the vessel. The inner vessel can have an inside diameter of at least 50 inches
(1.27 m). The space between the inner and outer vessels defines a flue. The perforated
grid plate within the inner vessel can have an upper surface perforated with a pattern of
overlapping, generally conical depressions and a lower surface, optionally overlapping by
at least 17%. The fluid path extends upwardly through the perforated grid plate and is a
conduit along which a fluid flows through the grid plate. The fluid will fiuidize a
particulate material, such as a catalyst, disposed above the grid plate in the inner vessel.

Documents:

00602-kolnp-2005-abstract.pdf

00602-kolnp-2005-claims.pdf

00602-kolnp-2005-description complete.pdf

00602-kolnp-2005-drawings.pdf

00602-kolnp-2005-form 1.pdf

00602-kolnp-2005-form 2.pdf

00602-kolnp-2005-form 3.pdf

00602-kolnp-2005-form 5.pdf

00602-kolnp-2005-international publication.pdf

602-KOLNP-2005-ASSIGNMENT.pdf

602-KOLNP-2005-CANCELLED PAGES.pdf

602-KOLNP-2005-CORRESPONDENCE.pdf

602-KOLNP-2005-EXAMINATION REPORT.pdf

602-KOLNP-2005-FORM 13.pdf

602-KOLNP-2005-FORM 18.pdf

602-KOLNP-2005-FORM 26.pdf

602-KOLNP-2005-GRANTED-ABSTRACT.pdf

602-KOLNP-2005-GRANTED-CLAIMS.pdf

602-KOLNP-2005-GRANTED-DESCRIPTION (COMPLETE).pdf

602-KOLNP-2005-GRANTED-DRAWINGS.pdf

602-KOLNP-2005-GRANTED-FORM 1.pdf

602-KOLNP-2005-GRANTED-FORM 2.pdf

602-KOLNP-2005-GRANTED-FORM 3.pdf

602-KOLNP-2005-GRANTED-FORM 5.pdf

602-KOLNP-2005-GRANTED-SPECIFICATION-COMPLETE.pdf

602-KOLNP-2005-INTERNATIONAL PUBLICATION.pdf

602-KOLNP-2005-INTERNATIONAL SEARCH REPORT & OTHERS.pdf

602-KOLNP-2005-OTHERS.pdf

602-KOLNP-2005-PETITION UNDER RULE 137.pdf

602-KOLNP-2005-REPLY TO EXAMINATION REPORT.pdf

abstract-00602-kolnp-2005.jpg


Patent Number 259419
Indian Patent Application Number 602/KOLNP/2005
PG Journal Number 11/2014
Publication Date 14-Mar-2014
Grant Date 12-Mar-2014
Date of Filing 08-Apr-2005
Name of Patentee CHEVRON PHILLIPS CHEMICAL COMPANY, L.P.,
Applicant Address 10001 SIX PINES DRIVE, THE WOODLANDS, TEXAS 77387, U.S.A.
Inventors:
# Inventor's Name Inventor's Address
1 DALC A. ZELLERS 800 BROOKHOLLOW LANE BARTLESVILLE, OKLAHOMA 74006 USA
2 JOHN D. HOTTOVY 345 ROBIN AVENUE BARTLESVILLE, OKLAHOMA 74006 U.S.A. CITIZENSHIP: U.S.A.
3 JAMES E. HEIN 4015 HALLMARK FAIR HOUSTON, TEXAS 77059 U.S.A.
PCT International Classification Number B01J 8/44
PCT International Application Number PCT/US2003/028724
PCT International Filing date 2003-09-12
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10/457,236 2003-06-09 U.S.A.
2 60/410,141 2002-09-12 U.S.A.