Description:FIELD OF THE INVENTION
Present invention provides method of reducing lump formation inside polypropylene reactor during Polypropylene Gas-phase Agitated bed Reactor Technology wherein the method involves injecting anti-static chemical in the reactor. The invention introduces innovative measures to mitigate the adverse effects of static charge generation and subsequent lump and sheet formation, thereby enhancing the efficiency and reliability of such reactors.

BACKGROUND OF THE INVENTION
Polymers play a crucial role in numerous aspects of our daily lives and have significant importance in various fields. Polymers have become indispensable materials in modern society, finding extensive use in a multitude of applications due to their diverse properties and functionalities. These Synthetic macromolecules play a crucial role in various aspects of our daily lives, impacting industries such as packaging, automotive, construction, textiles, healthcare, and more. Among the vast array of Synthetic polymers, polypropylene (PP) stands out as one of the most widely utilized and versatile materials, offering a myriad of advantages that have made it indispensable in numerous sectors. Polypropylene (PP) is a thermoplastic polymer that is widely used in various industries due to its unique properties and numerous advantages. The importance of polypropylene production lies in its versatility, lightweight nature, chemical resistance, durability, cost-effectiveness, recyclability, thermal stability, and electrical insulation properties. These qualities have made it a widely used material across various industries, contributing to economic growth and technological advancements. The significance of polypropylene production extends beyond its inherent properties. Its versatility, cost-effectiveness, and performance characteristics have fuelled advancements in various industries, contributing to economic growth and technological progress. Polypropylene's adaptability has led to innovations in packaging, automotive components, medical devices, textiles, and more, enhancing the quality of life and promoting industrial development.

There have been several technologies available for manufacture of polypropylene/ polymers, such as gas phase, slurry phase, emulsion polymer technologies. Gas-phase agitated bed polypropylene (PP) reactors represent a widely used technology for polymerization processes, offering advantages such as excellent heat and mass transfer characteristics, high product purity, and operational flexibility. These reactors play a pivotal role in the production of various polymers, including polyolefins like polypropylene.

However, despite their many advantages, gas-phase agitated bed PP reactors often encounter significant operational challenges that can hamper their effectiveness. One of the most prominent challenges is the formation of lumps and sheeting within the reactor.

Lumps and sheeting refer to the aggregation of polymer particles within the reactor, leading to blockages and operational disruptions. These formations can obstruct the flow of reactants and heat transfer, negatively impacting product quality and reactor performance. Additionally, the accumulation of lumps and sheets can result in increased downtime and maintenance costs. The generation of static current within the agitated polymer bed is a primary factor responsible for the occurrence of lumps and sheeting. The frictional interactions among polymer particles, as well as between the particles and reactor surfaces, lead to the accumulation of static charges. These charges attract and bind polymer particles together, giving rise to lumps and sheets.

The existing designs of gas-phase agitated bed PP reactors generally lack effective measures to suppress the generation of static charges within the reactor. Consequently, the issue of lumps and sheeting remains a persistent challenge, necessitating frequent interventions and operational interruptions to address blockages and maintain reactor efficiency.

The need for innovation in gas-phase agitated bed PP reactor technology is evident, particularly in addressing the issues of static charge generation, lumps, and sheeting formation. The present invention aims to provide effective solutions to mitigate these challenges, enhancing the reliability and performance of gas-phase agitated bed reactors in polymerization processes.

In the following sections, we describe the inventive methods and systems that enable the reduction of static charge generation and the prevention of lumps and sheeting formation, ultimately contributing to the improved operation and productivity of gas-phase agitated bed reactors.

OBJECT OF THE INVENTION
The principal objective of this invention is to develop innovative methods and systems that effectively mitigate the formation of lumps and sheeting inside Gas-phase Agitated bed Polypropylene reactors. This includes preventing blockages in the powder discharge lines and enhancing the overall reactor throughput.

Another object of the present invention is to improve the operational efficiency of Gas-phase Agitated bed Polypropylene reactors by eliminating or significantly reducing the occurrence of lump and sheet formation. This improvement leads to reduced downtime and maintenance, ultimately enhancing productivity.

Another object of the present invention is to provide a process of producing polypropylene in the Gas-phase Agitated bed polypropylene reactor with reduced formation of Static Charge and hence, lumps inside the reactor.

Another object of the present invention is to increase the reactor operating throughput of Gas-phase Agitated bed polypropylene Reactor up to at least 85% of design, enhancing the reliability and stability of Gas-phase Agitated bed Polypropylene reactor technology, making it a dependable choice for polymer manufacturers across various industries.

SUMMARY OF THE INVENTION
The conventional design of Gas Phase reactors lacks any provisions to mitigate the problem of static charge accumulation within the reactor. This invention proposes the introduction of an Anti-Static agent into the reactor to dissipate the accumulated static charge generated during operation. By reducing the static charge to an acceptable level, this innovation aims to effectively address the issue of lump and sheeting formation within the reactor. Consequently, this approach enables the possibility of achieving higher throughput levels in the reactor.

Accordingly, in main aspect, the present invention provides a method of reduction of lump formation inside a Gas-phase Agitated Bed Polypropylene (PP) Reactor, comprising the steps of:
a) providing a Gas-phase Agitated Bed Polypropylene (PP) Reactor;
b) selected from Synthetic Ethoxylated Amine into the PP reactor along with feed monomer propylene during the polymerization process; and
c) adjusting the injection rate and concentration of the anti-static chemical to monitor the static charge build up within the reactor and mitigate lump formation in the reactor.

In another aspect, the present invention provides method of reduction of lump formation inside a Gas-phase Agitated Bed Polypropylene (PP) Reactor, comprising the steps of:
(a) introducing Synthetic Ethoxylated Amine, into the Gas-phase Agitated bed PP reactor during the polymerization process at controlled rate; and
(b) reducing the accumulation of static charge within the Gas-phase Agitated bed PP reactor.

In another aspect, the present invention provides a system for minimizing lump formation in a Gas-phase Agitated Bed Polypropylene (PP) Reactor, comprising:
a) a Gas-phase Agitated Bed Polypropylene (PP) Reactor configured for polymerization, the reactor equipped with a helical agitator designed to create and maintain a uniform and consistent reaction environment;
b) an injection system configured to introduce an anti-static chemical selected from Synthetic Ethoxylated Amine into the reactor; and
c) a control unit adapted to adjust the injection rate and concentration of the anti-static chemical based on real-time data related to static charge build up and reactor conditions.

BRIEF DESCRIPTION OF DRAWINGS
The present invention will now be described in detail with reference to the accompanying drawings.

These and other features, aspects and advantages of the present drawings will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represents like parts throughout the drawings, wherein:
Fig. 1: Block Flow Diagram showcasing Gas-phase Agitated bed PP reactor and polypropylene manufacturing Process ;
Fig. 2: a detailed diagram of the Synthetic Ethoxylated Amine injection system installed in the Gas-phase Agitated bed PP reactor;
Fig. 3: Flowchart showcasing production of polypropylene manufacturing Process in Gas-phase Agitated bed PP reactor containing Synthetic Ethoxylated Amine Dosing System;
Fig. 4: Table 1 depicts day-average data for the mentioned date;
Fig. 5: Reactor Operation Before Synthetic Ethoxylated Amine Dosing; and
Fig. 6: Reactor Operation After Synthetic Ethoxylated Amine Dosing.

DETAILED DESCRIPTION OF THE INVENTION
For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.
Reference throughout this specification to “an aspect”, “another aspect” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrase “in an embodiment”, “in another embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by "comprises...a" does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.
Herein, “Polypropylene” and “PP” are used interchangeably throughout the specification.

Herein, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, to provide a thorough understanding of embodiments of the disclosed subject matter.

Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.
Referring to Fig. 1 illustrating a typical Gas-phase Agitated bed Polypropylene Manufacturing Process wherein the Gas-phase Agitated bed polypropylene reactor contains at least one of the Homopolymer and Random Copolymer reactor, at least one of the Impact copolymer reactor, at least one of the discharge vessel, at least one Purge vessel, an extruder attached to underwater die face cutter and at least one degassing unit.

Further, referring to Fig. 1 in conjunction with Fig. 3 illustrating the detailed process of manufacturing polypropylene in a typical Gas-phase Agitated bed polypropylene reactor, wherein the process includes the steps of:
1. Fresh propylene sourced from the Outside Battery Limit (OSBL) and the raw propylene undergoes a purification process to remove impurities and ensure the feedstock's quality. Additionally, the required catalyst (Ziegler-Natta catalyst), co-catalyst (Tri-Ethyl-Aluminium), hydrogen, and stereo-modifier (Silane) are prepared and mixed with the propylene feedstock and passed to PP reactor.
2. Synthetic Ethoxylated Amine injected from Dosing system [200] at a controlled rate is mixed with monomer propylene feedstock entering into the PP reactor through silane feeding line.
3. The polymerization process takes place within the Gas-phase Agitated bed PP reactor. This reactor operates as a gas-phase stirred reaction vessel. Heat removal during the exothermic polymerization reaction is managed using evaporative cooling. Liquid propylene entering the reactor vaporizes upon contact with the hot reactor contents, effectively absorbing the exothermic heat generated by the reaction. This vaporization process helps maintain the reactor at the desired temperature.
4. Reaction gases are continuously withdrawn from the top of the reactor and passed through a filtration system. The overhead vapour, referred to as "Recycle Gas," is then condensed and pumped back into the reactor as a coolant. Non-condensable gases, primarily hydrogen (H2) and nitrogen (N2), are compressed and also returned to the reactor to maintain the desired gas composition.
5. The polypropylene product, in the form of powder, is discharged from the reactor using two powder discharge lines. Along with the powder, unreacted gases known as carrier gas are also expelled. In a downstream discharge vessel, the carrier gas and the powder resins undergo separation.
6. The carrier gas is routed through a cyclone and filter to remove any residual powder. It is then subjected to a washing process with white oil in a wash tower to further eliminate any remaining powder particles. After the wash, the carrier gas is compressed and directed to a downstream Fluid Catalytic Cracking (FCC) unit for further conditioning and processing.
7. The powder from the discharge vessel is directed to two parallel purge vessels. Nitrogen is employed to purge the powder, eliminating any residual monomers. The overhead gas from the purge vessels is sent back to the carrier gas system for recovery and reuse.
8. The purged PP powder is pneumatically conveyed using a Nitrogen system to powder silos for storage. Subsequently, the powder product from these silos is directed to an extruder. In the extruder, the polymer powder is mixed, melted, homogenized, and extruded through a die plate.
9. Palletisation of the final product is carried out in an underwater pelletizer, where the extruded polymers are cut into pellets by a set of rotating knives.
10. The polymer/water slurry from the underwater pelletizer is transported to a centrifugal dryer, where polymer and water are efficiently separated. The water is recycled to a pellet water tank. The cooled pellets are pneumatically conveyed to pellet blending silos by an air conveying system. In the blending silos, the pellets undergo homogenization.
11. After homogenization in the blending silos, the pellets are conveyed to a bagging and palletizing system for final packaging and distribution.

This detailed description outlines the entire process of producing polypropylene using a Gas-phase Agitated bed reactor, from the preparation of feedstock to the final packaging of the polymer pellets. The inventive aspects primarily focus on the introduction of an Anti-Static agent i.e. Synthetic Ethoxylated Amine, the management of static charge, and the optimization of reactor efficiency as referred in Fig. 2.

Referring to Fig. 2, illustrates a detailed diagram of the Synthetic Ethoxylated Amine injection system installed in the Gas-phase Agitated bed PP reactor. The synthetic ethoxylated amine injection system, including components such as metering pumps, flow measurement devices, and their connections to the reactor and Silane feeding line. The the dosing system comprises of a holding tank containing Synthetic Ethoxylated Amine passed to the PP reactor through a filter wherein injecting of the anti-static agent i.e. Synthetic Ethoxylated Amine to the reactor from holding tank is controlled by a uploading pump. The injection system for Synthetic Ethoxylated Amine into the reactor is depicted in Figure-2, illustrating the precise control and monitoring mechanisms employed to resolve the issue of lump formation.

Referring to Fig. 3, illustrating a flow chart of production process of polypropylene in Gas-phase Agitated bed PP reactor connected to a “Synthetic Ethoxylated Amine Dosing System”. In the Process Flow chart, method [100] for the production of polypropylene (PP) using a Gas-phase Agitated bed PP reactor, includes an additional process step and components for the "Synthetic Ethoxylated Amine Dosing System [200]". As represented within the Fig. 3 in reference to Fig. 2 which showcases the connection between the holding tank containing the Synthetic Ethoxylated Amine, the filter, and the uploading pump responsible for controlled injection of the anti-static agent (Synthetic Ethoxylated Amine) into the reactor.

The the method [100] includes a step [101] involving a Feed stock introduction and preparation in PP reactor: This step requires introduction of purified propylene obtained from Outside Battery Limit (OSBL). Additionally, the required catalyst, co-catalyst, hydrogen, and stereo-modifier (Silane) are prepared and mixed with the propylene feedstock. Moreover, the Synthetic Ethoxylated Amine from amine dosing system is injected in ratio with the above the feed monomer propylene at a controlled rate of 20-25 ppm and wherein the Synthetic Ethoxylated Amine is injected through silane feeding line.
Further, method [100] comprises of Step [102] involving a Polymerization in Gas-Phase Stirred Reaction: In this step, the polymerization process takes place within the Gas-phase Agitated bed PP reactor. This reactor operates as a gas-phase stirred reaction vessel. Heat removal during the exothermic polymerization reaction is managed using evaporative cooling. Liquid propylene entering the reactor vaporizes upon contact with the hot reactor contents, effectively absorbing the exothermic heat generated by the reaction. This vaporization process helps maintain the reactor at the desired temperature.
Further, method [100] comprises of Step [103] involving gas removal and filtration: In this step, reaction gases are continuously withdrawn from the top of the reactor and passed through a filtration system. The overhead vapour, referred to as "Recycle Gas," is then condensed and pumped back into the reactor as a coolant. Non-condensable gases, primarily hydrogen (H2) and nitrogen (N2), are compressed and also returned to the PP reactor to maintain the desired gas composition.
Further, method [100] comprises of Step [104] involving Polypropylene Product Discharge: In this step, the polypropylene product, in the form of powder, is discharged from the PP reactor using two powder discharge lines. Along with the powder, unreacted gases known as carrier gas are also expelled. In a downstream discharge vessel, the carrier gas and the powder resins undergo separation.
Further, method [100] comprises of Step [105] involving Carrier Gas Processing: In this step, the carrier gas is routed through a cyclone and filter to remove any residual powder. It is then subjected to a washing process with white oil in a wash tower to further eliminate any remaining powder particles. After the wash, the carrier gas is compressed and directed to a downstream Fluid Catalytic Cracking (FCC) unit for further conditioning and processing.
Further, method [100] comprises of Step [106] involving Powder Purging: In this step, the powder from the discharge vessel is directed to two parallel purge vessels. Nitrogen is employed to purge the powder, eliminating any residual monomers. The overhead gas from the purge vessels is sent back to the carrier gas system for recovery and reuse.
Further, method [100] comprises of Step [107] involving Pneumatic Conveying and Palletisation: In this step, the purged PP powder is pneumatically conveyed using a Nitrogen system to powder silos for storage. Subsequently, the powder product from these silos is directed to an extruder. In the extruder, the polymer powder is mixed, melted, homogenized, and extruded through a die plate. Palletisation of the final product is carried out in an underwater pelletizer, where the extruded polymers are cut into pellets by a set of rotating knives.
Further, method [100] comprises of Step [108] involving Drying and Blending: In this step, the polymer/water slurry from the underwater pelletizer is transported to a centrifugal dryer, where polymer and water are efficiently separated. The water is recycled to a pellet water tank. The cooled pellets are pneumatically conveyed to pellet blending silos by an air conveying system. In the blending silos, the pellets undergo homogenization.
Further, method [100] comprises of Step [109] involving Bagging and Palletizing: In this step, after homogenization in the blending silos, the pellets are conveyed to a bagging and palletizing system for final packaging and distribution.

Polypropylene (PP) production is a crucial industrial process, which is nowadays produced inside the Gas-phase Agitated polypropylene Reactor. The gas phase agitated polypropylene reactor technology used for production of polypropylene utilizes a reactor equipped with a helical agitator to maintain a consistent reaction environment. The reaction mainly involves Propylene as the monomer and employs a typical Ziegler-Natta catalyst. TEAL (Tri-Ethyl-Aluminium) is used as a co-catalyst, and Silane acts as a stereo-modifier to control the properties of the PP product. Hydrogen functions as a polymer chain terminating agent during the reaction. To maintain the reactor's heat balance and dissipate the heat generated during polymerization, the circulating recycle gas from the reactor top undergoes cooling and liquefaction in a shell and tube heat exchanger. The resulting cooled liquid is then reintroduced into the reactor. The powder product obtained from the reaction is discharged through two powder discharge lines, ensuring a consistent powder level within the reactor.

The above the PP production often faces challenges related to lumps and sheeting formation inside the Gas-phase Agitated polypropylene Reactor which ultimately leads to blockages in the powder discharge lines. This chronic issue can lead to operational disruptions, decreased efficiency, and increased maintenance. To address this problem, an innovative method was developed and experimentally validated. Present invention provides a novel approach to resolve the persistent issue of lump formation in the Gas-phase Agitated Bed PP Reactor. The present invention provides a controlled injection of an anti-static agent, specifically Synthetic Ethoxylated Amine, into the reactor. This intervention successfully mitigated the problem of lump formation.

An embodiment of the present invention involves a novel approach to mitigate static charge accumulation within Gas Phase PP reactors, which have traditionally lacked provisions for addressing this issue. In this embodiment, an Anti-Static agent, specifically a Synthetic Ethoxylated Amine, is introduced directly into the reactor during its operation.

The introduction of the Anti-Static agent serves as a proactive measure to dissipate the static charge that naturally accumulates within the reactor during the polymerization process. This static charge build up is typically attributed to the frictional interactions among polymer particles and between polymer particles and the reactor's internal surfaces. By reducing the static charge to an acceptable level, this embodiment significantly improves the operational efficiency of Gas Phase reactors. The prevention of lump and sheeting formation ensures unobstructed flow within the reactor, thereby minimizing downtime and maintenance requirements. Moreover, the enhanced stability and consistency of polymerization contribute to achieving higher throughput levels in the reactor.

Accordingly, in one embodiment, the present invention provides a method of reduction of lump formation inside a Gas-phase Agitated Bed Polypropylene (PP) Reactor, comprising the steps of:
a) providing a Gas-phase Agitated Bed Polypropylene (PP) Reactor;
b) injecting an anti-static chemical selected from Synthetic ethoxylaed Amine into the reactor along with feed monomer propylene during the polymerization process; and
c) adjusting the injection rate and concentration of the anti-static chemical to monitor the static charge build up within the reactor and mitigate lump formation in the reactor.

In another embodiment, the Synthetic Ethoxylated Amine is introduced in an amount ranging from 20 to 25 ppm (parts per million) relative to the feed monomer propyleneutilized in the process is Polymer Grade Propylene (PGP), and the PGP is sourced from the refinery's Fluidized Catalytic Cracker Unit – Propylene Recovery Unit (FCCU-PRU) plant, wherein a circulation of the PGP from the FCCU-PRU plant to storage bullets located in the offsite area (OSBL) before being fed into the Polymer Production Unit (PPU) plant for use in the polymerization process.

In another embodiment, the introduction of Synthetic Ethoxylated Amine into the reactor effectively mitigated the issue of reactor powder product discharge line obstruction (choking), thereby resulting in a substantial throughput enhancement of approximately 15-20%.

In another embodiment, the present invention provides method of reduction of lump formation inside a Gas-phase Agitated Bed Polypropylene (PP) Reactor, comprising the steps of:
(a) introducing an Anti-Static agent selected from Synthetic Ethoxylated Amine at a controlled rate into the Gas-phase Agitated bed PP reactor during the polymerization process; and
(b) reducing the accumulation of static charge within the Gas-phase Agitated bed PP reactor.

In another embodiment, the reduction in static charge accumulation results in a significant increase in the throughput of the Gas-phase Agitated bed PP reactor, with an approximate increase of about 20%.

In another embodiment, the present invention provides a system for minimizing lump formation in a Gas-phase Agitated Bed Polypropylene (PP) Reactor, comprising:
a) a Gas-phase Agitated Bed Polypropylene (PP) Reactor configured for polymerization, the reactor equipped with a helical agitator designed to create and maintain a uniform and consistent reaction environment;
b) an injection system configured to introduce an anti-static chemical selected from Synthetic Ethoxylated Amine into the reactor; and
c) a control unit adapted to adjust the injection rate and concentration of the anti-static chemical based on real-time data related to static charge buildup and reactor conditions.

In another embodiment, the gas phase agitated bed PP reactor system of the present invention utilizes a control unit which is a controlled and monitored dosing system [200] for accurately regulating the flow rate and content of Synthetic Ethoxylated Amine introduced into the Gas-phase Agitated bed PP reactor, wherein the injection rate of Synthetic Ethoxylated Amine is controlled by means of adjusting the dosing pump speed, the pump is having a VFD (Variable Frequency Drive) facility) in an automated manner from a DCS (Distributed control system), wherein the control unit further comprises diaphragm-type metering pumps that control the flow of the Synthetic Ethoxylated Amine. This controlled and monitored system ensures precise control of the flow rate and content of Synthetic Ethoxylated Amine throughout the polymerization process, thereby preventing deviations in the required PP product specifications.

In another embodiment, the reactor further comprises a monomer and catalyst management unit for utilization of Propylene as the primary monomer for the polymerization process, deployment of a typical Ziegler-Natta catalyst to initiate and facilitate polymerization, incorporation of Tri-Ethyl-Aluminium (TEAL) as a co-catalyst to enhance the polymerization process, introduction of hydrogen as a polymer chain terminating agent during the polymerization reaction, and inclusion of Silane as a stereo-modifier, utilized to regulate and control the properties of the resulting polypropylene (PP) product.
In one embodiment, a thermal management unit is having an exothermic polymerization reaction that generates heat during the process, an efficient heat dissipation system that involves the circulation of recycle gas from the top of the reactor, a shell and tube heat exchanger, specifically designated as the Recycle Gas (RG) Condenser, to cool and liquefy the circulating gas, and reintroduction of the resulting cooled liquid from the RG Condenser back into the reactor, a vital step in maintaining and regulating the temperature of the reactor bed.
In one embodiment, a powder discharge system is used for discharge of polypropylene powder produced after the polymerization reaction into a designated powder discharge vessel and implementation of two distinct powder discharge lines to ensure the consistent maintenance of a predefined powder level within the reactor.

In another embodiment, the injection system comprises an unloading pump for unloading Synthetic Ethoxylated Amine from a drum and storing in a vessel.
In one embodiment, a dosing pump is equipped with a filter and connected to the vessel for controlled injection into the reactor.

Accordingly, in one example, the Synthetic Ethoxylated Amine was injected into the Gas-phase Agitated Bed polypropylene Reactor at a controlled rate to counteract static charge accumulation, a major contributor to lump formation. The injection rate of Synthetic Ethoxylated Amine was carefully controlled within the range of 20-25 ppm relative to the feed monomer propylene. To ensure precise control of the Synthetic Ethoxylated Amine flow, sophisticated diaphragm-type metering pumps were employed. The flow of Synthetic Ethoxylated Amine was accurately measured using state-of-the-art mass-flow meters, ensuring precise dosing. To expedite the process, the discharge from the metering pump for Synthetic Ethoxylated Amine was connected to the Silane feeding line to the reactor.

Comparison of present invention with known technologies and Results:
Observations of the Gas-phase Agitated bed PP reactor in its typical configuration revealed a critical operational limitation. When the reactor operates beyond 65% of its designed throughput level, a substantial static charge accumulates within the reactor. This phenomenon has historically led to the formation of troublesome lumps, effectively imposing a cap on the achievable throughput. The existing reactor design, illustrated in its typical configuration, provides no effective provision for addressing or eliminating static charge build up or resolving the issue of lump formation within the reactor.

In response to this chronic challenge, a series of experiments were conducted as part of this inventive approach. These experiments aimed to resolve the persistent problem of lump formation within the reactor. The core innovation involved the controlled injection of an Anti-Static agent (Synthetic Ethoxylated Amine) directly into the Gas-phase Agitated bed PP reactor.

Specifically, the Anti-Static agent used in these experiments was Synthetic Ethoxylated Amine. This agent was introduced into the reactor in a carefully controlled manner, maintaining a precise ratio with the feed monomer propylene at a rate ranging from 20 to 25 parts per million (ppm). To ensure the accurate control of the Anti-Static agent flow into the reactor, sophisticated diaphragm-type metering pumps were employed.

The flow of Synthetic Ethoxylated Amine into the reactor was meticulously measured using the most accurate mass-flow meter available. This approach enabled precise control and monitoring of the Anti-Static agent injection process, ensuring a well-regulated dosage within the reactor.

RESULTS
The results of these experiments were nothing short of transformative. The controlled injection of Synthetic Ethoxylated Amine effectively dissipated the static charge generated within the Gas-phase Agitated bed PP reactor. As a direct consequence, the chronic issue of lump formation was successfully resolved. This breakthrough not only prevented the formation of lumps but also enabled the reactor to operate efficiently beyond the previous limitation of 65% of its designed throughput level. The reactor operating throughput was increased from about 65% of design to about 85% of design.

The innovative approach of introducing the Anti-Static agent into the reactor through sophisticated metering pumps, as demonstrated in these experiments, offers a practical and reliable solution to a long-standing challenge. It opens up the potential for significantly higher throughput levels and enhanced operational stability in Gas-phase Agitated bed PP reactors, marking a substantial advancement in polymerization technology. There was no negative impact on the PP product properties during the experiment. There was no negative impact on any of the reactor operating parameters during the experiments.

Figure-2 explains the working of ATMER (Synthetic Ethoxylated Amine) dosing system. ATMER chemical is unloaded from “ATMER Drum” with the help of “ATMER Unloading Pump” and stored in the “ATMER Vessel”. ATMER stored in the “ATMER Vessel” is fed to the “PP Reactor System” via “Filter” and downstream “ATMER Dosing Pump”. With the help of ATMER (Synthetic Ethoxylated Amine) feeding to reactor, the choking issue of reactor powder product discharge line was resolved, thereby the throughput was increased by 15-20%. The detailed data is as per Table 1. Feed monomer i.e. PGP (Polymer Grade Propylene) is produced in the refinery’s FCCU-PRU (Fluidized Catalytic Cracker Unit – Propylene Recovery Unit) plant. From FCCU-PRU, PGP is sent to the storage bullets in the offsite area (OSBL) from where the PGP is fed to PPU plant.

The system includes a gas phase agitated bed PP reactor system comprises of a reactor equipped with a helical agitator to maintain a consistent reaction environment. The reaction mainly involves Propylene as the monomer and employs a typical Ziegler-Natta catalyst, TEAL (Tri-Ethyl-Aluminium) is used as a co-catalyst, and Silane acts as a stereo-modifier to control the properties of the PP product. Hydrogen functions as a polymer chain terminating agent during the reaction.
The polymerization reaction is exothermic in nature and to dissipate the heat generated during polymerization, the circulating recycle gas from the reactor top undergoes cooling and liquefaction in a shell and tube heat exchanger i.e. Recycle Gas (RG) Condenser. The resulting cooled liquid is then reintroduced into the reactor to control reactor bed temperature. The polypropylene powder produced after reaction is discharged to powder discharge vessel through two powder discharge lines, ensuring a consistent powder level within the reactor.

The injection system configured to introduce an anti-static chemical selected from Synthetic Ethoxylated Amine into the reactor.

Figure-2 explains the working of ATMER (Synthetic Ethoxylated Amine) injection system. ATMER chemical is unloaded from “ATMER Drum” with the help of “ATMER Unloading Pump” and stored in the “ATMER Vessel”. ATMER stored in the “ATMER Vessel” is fed to the “PP Reactor System” via “Filter” and downstream “ATMER Dosing Pump”.

The control unit adapted to adjust the injection rate and concentration of the anti-static chemical based on real-time data related to static charge build up and reactor conditions.
The injection rate (Synthetic Ethoxylated Amine) is controlled by means of adjusting the ATMER dosing pump speed (as the pump is having the VFD (Variable Frequency Drive) facility) in an automated manner from the DCS (Distributed control system) as per the requirement. A high precision mass-flow meter is also installed at the downstream of “ATMER dosing Pump” to capture and monitor the real-time flow-rate of ATMER to the reactor. Based on the real-time data, this flow-rate is adjusted based on process requirement with the help of ATMER dosing pump VFD.

The controlled and monitored dosing system that regulates the flow rate and content of Synthetic Ethoxylated Amine
The injection rate (Synthetic Ethoxylated Amine) is controlled by means of adjusting the ATMER dosing pump speed (as the pump is having the VFD (Variable Frequency Drive) facility) in an automated manner from the DCS (Distributed control system) as per the requirement. A high precision mass-flow meter is also installed at the downstream of “ATMER dosing Pump” to capture and monitor the real-time flow-rate of ATMER to the reactor. Based on the real-time data, this flow-rate is adjusted based on process requirement with the help of ATMER dosing pump VFD.

The injection rate (Synthetic Ethoxylated Amine) is controlled by means of adjusting the ATMER dosing pump speed (as the pump is having the VFD (Variable Frequency Drive) facility) in an automated manner from the DCS (Distributed control system) as per the requirement. The injection rate is as per the table above.

Fig. 4: Table 1 depicts day-average data for the mentioned date.

Fig. 5: Reactor Operation Before Synthetic Ethoxylated Amine Dosing.

Fig. 6: Reactor Operation After Synthetic Ethoxylated Amine Dosing.

Through the innovative method described herein, the chronic problem of lump formation in Gas-phase Agitated Bed PP Reactors during PP production has been effectively addressed. The controlled injection of Synthetic Ethoxylated Amine has proven to be a successful strategy, enhancing reactor performance and reliability. , Claims:
1. A method for the reduction of lump formation inside a Gas-phase Agitated Bed Polypropylene (PP) Reactor, comprising the steps of:
a) providing a Gas-phase Agitated Bed Polypropylene (PP) Reactor;
b) injecting an anti-static chemical selected from Synthetic Ethoxylated Amine into the PP reactor along with feed monomer propylene during the polymerization process; and
c) adjusting the injection rate and concentration of the anti-static chemical to monitor the static charge build up within the reactor and mitigate lump formation in the reactor.

2. The method as claimed in claim 1, wherein said Synthetic Ethoxylated Amine is introduced in an amount ranging from 20 to 25 ppm (parts per million) relative to the feed monomer propylene, said feed monomer propylene utilized in the process is Polymer Grade Propylene (PGP).

3. The method as claimed in claim 1, wherein said feed monomer propylene is obtained from Outside Battery Limit (OSBL), said feed monomer propylene is added to PP reactor along with a Ziegler-Natta catalyst, Tri-Ethyl-Aluminium co-catalyst, hydrogen, and stereo-modifier (Silane).

4. The method as claimed in claim 1, wherein the introduction of Synthetic Ethoxylated Amine into the reactor effectively mitigated the issue of reactor powder product discharge line obstruction (choking), thereby resulting in a substantial throughput enhancement of approximately 15-20%.

5. The method as claimed in claim 1, wherein said Synthetic Ethoxylated Amine injected into the PP reactor, reduces the accumulation of static charge within the Gas-phase Agitated bed PP reactor.

6. The method as claimed in claim 1, wherein said Synthetic Ethoxylated Amine injected into the PP reactor, increase the throughput of the Gas-phase Agitated bed PP reactor by about 20%.

7. A system for minimizing lump formation in a Gas-phase Agitated Bed Polypropylene (PP) Reactor, comprising:
a) a Gas-phase Agitated Bed Polypropylene (PP) Reactor configured for polymerization, said reactor equipped with a helical agitator designed to create and maintain a uniform and consistent reaction environment;
b) an injection system configured to introduce an anti-static chemical selected from Synthetic Ethoxylated Amine into the reactor; and
c) a control unit adapted to adjust the injection rate and concentration of the anti-static chemical based on real-time data related to static charge build up and reactor conditions.

8. The system as claimed in claim 7, wherein said control unit is a controlled and monitored dosing system that regulates the flow rate and content of Synthetic Ethoxylated Amine introduced into the Gas-phase Agitated bed PP reactor, wherein said injection rate of Synthetic Ethoxylated Amine is controlled by means of adjusting the dosing pump speed, said pump is having a VFD (Variable Frequency Drive) facility) in an automated manner from a DCS (Distributed control system), wherein said control unit further comprises diaphragm-type metering pumps that control the flow of the Synthetic Ethoxylated Amine.

9. The system as claimed in claim 7, wherein said reactor further comprises:
a monomer and catalyst management unit for utilization of Propylene as the primary monomer for the polymerization process, deployment of a typical Ziegler-Natta catalyst to initiate and facilitate polymerization, incorporation of Tri-Ethyl-Aluminium (TEAL) as a co-catalyst to enhance the polymerization process, introduction of hydrogen as a polymer chain terminating agent during the polymerization reaction, and inclusion of Silane as a stereo-modifier, utilized to regulate and control the properties of the resulting polypropylene (PP) product;
a thermal management unit having an exothermic polymerization reaction that generates heat during the process, an efficient heat dissipation system that involves the circulation of recycle gas from the top of the reactor, a shell and tube heat exchanger, specifically designated as the Recycle Gas (RG) Condenser, to cool and liquefy the circulating gas, and reintroduction of the resulting cooled liquid from the RG Condenser back into the reactor, a vital step in maintaining and regulating the temperature of the reactor bed; and
a powder discharge system for discharge of polypropylene powder produced after the polymerization reaction into a designated powder discharge vessel and implementation of two distinct powder discharge lines to ensure the consistent maintenance of a predefined powder level within the reactor.

10. The system as claimed in claim 7, wherein said injection system comprises:
an unloading pump for unloading Synthetic Ethoxylated Amine from a drum and storing in a vessel; and
a dosing pump equipped with a filter and connected to said vessel for controlled injection into said reactor.