Abstract: A manufacturing system for producing polyolefin includes a polymerization reactor, a flash chamber, and a purge column. In certain embodiments, the purge column may receive a solids stream directly from the flash chamber. Further, the purge column may function as a feed tank for an extruder within an extrusion/loadout system. According to certain embodiments, the manufacturing system may be configured to consume less than 445 kilowatt-hours of energy per metric ton of polyolefin produced based on consumption of electricity, steam, and fuel gas.

Abstract: A manufacturing process for producing polyolefin, having a feed system, a reactor system including at least one polymerization reactor, a diluent/monomer recovery system, a fractionation system, and an extrusion/loadout system having an extruder. The manufacturing process is configured to consume less than 325 kilowatt-hours of electricity per metric ton of polyolefin produced.

Abstract: A manufacturing process for producing polyolefin, having a feed system, a reactor system including at least one polymerization reactor, a diluent/monomer recovery system, a fractionation system, and an extrusion/loadout system having an extruder. The manufacturing process is configured to consume less than 325 kilowatt-hours of electricity per metric ton of polyolefin produced.

Abstract: An olefin polymerization process and apparatus wherein a fluid slurry comprising monomer, diluent and catalyst is circulated in a continuous loop reactor by two or more pumps. The process and apparatus allow operating the reaction at significantly higher solids content in the circulating fluid slurry. In a preferred embodiment, the fluid slurry is circulated by two impellers arranged so that the downstream impeller benefits from the rotational energy imparted by the upstream impeller. An olefin polymerization process operating at higher reactor solids by virtue of more aggressive circulation has improved efficiencies, particularly in larger-volume reactors.

Abstract: Multiple components are selected, conveyed, and measured in a polymerization system. A control system adjusts the system variables to the desired values. Portions of the components can be fed to a pre-contactor before introduction into the polymerization reactor. The catalyst component concentrations and residence times are tightly controlled in the pre-contactor to affect product properties. The pre-contactor can be a single or multiple combinations of a CSTR or plug flow pre-contactors.