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