Manufacturing ethylene interpolymer products at higher production rate

Abstract

This disclosure relates to an improved continuous solution polymerization process wherein production rate is increased. Process solvent, ethylene, optional comonomers, optional hydrogen and a bridged metallocene catalyst formulation are injected into a first reactor to form a first ethylene interpolymer. Optionally, process solvent, ethylene, optional comonomers, optional hydrogen and a bridged metallocene catalyst formulation are injected into a second reactor forming a second ethylene interpolymer. The first and second reactors may be configured in series or parallel modes of operation. Optionally, a third ethylene interpolymer is formed in a third reactor, wherein a homogeneous catalyst formulation or a heterogeneous catalyst formulation is employed. In solution, the first, optional second and optional third ethylene interpolymers are combined, the catalyst is deactivated, the solution is optionally passivated and following a phase separation process an ethylene interpolymer product is recovered.