A Novel Method of Measuring the Phase Behavior and Rheology of Polyethylene Solutions Using a Multi-Pass Rheometer

摘要

The Advanced SCLAIRTECHTM Technology process is used to manufacture Linear Low Density Polyethylene using solution polymerization. In this process ethylene is polymerized in an inert solvent, which is subsequently evaporated and recycled. The reactor effluent in the process is a polymer solution containing the polyethylene product, which is separated from the solvent and unconverted ethylene/co-monomer before being extruded and pelletized. The design of unit operations in this process requires a detailed understanding of the thermophysical properties, phase behaviour and rheology of polymer containing streams at high temperature and pressure, and over a wide range of composition. This paper describes a device used to thermo-rheologically characterize polymer solutions under conditions prevailing in polymerization reactors, downstream heat exchangers and attendant phase separation vessels. The downstream processing of the Advanced SCLAIRTECHTM Technology reactor effluent occurs at temperatures and pressures near the critical point of the solvent and co-monomer mixture. In addition, the process trajectory encompasses regions of liquid-liquid and liquid-liquid-vapour co-existence, which are demarcated by a `cloud point' curve. Knowing the location of this phase boundary is essential for the design of downstream devolatilization processes and for optimizing operating conditions in existing plants. In addition, accurate solution rheology data are required for reliable equipment sizing and design. At NOVA Chemicals, a robust high-temperature and high-pressure-capable version of the Multi-Pass Rheometer (MPR) is used to provide data on solution rheology and phase boundary location. This sophisticated piece of equipment is used to quantify the effects of solvent types, comonomer, and free ethylene concentration on the properties of the reactor effluent. An example of the experimental methodology to characterize a polyethylene solution with hexane solvent, and the ethylene dosing technique developed for the MPR will be described. TMAdvanced SCLAIRTECH is a trademark of NOVA Chemicals.