Methods and systems for multi-component catalyst formulation

Abstract

A system for combining the components of a multi-component catalyst system comprising at least four chambers with flow passageway means connecting the chambers in series. The catalyst components can include a transition metal, an electron donor and a co-catalyst, which are sequentially mixed together in the course of formulating a Ziegler-type system to be charged to an olefin polymerization reactor. The passages between the second and third chambers have valves. Each of the second and fourth chambers is provided with an inlet opening separate from the interconnecting flow passages and a vent opening separate from the inlet openings and the interconnecting flow passages. The chamber also has an outlet opening. This system also has flushing inlet passages for each of the four chambers which are connected to a manifold adapted to be connected to a source of nitrogen. In operation of the system, the catalyst components in the first and second chambers are discharged into the third chamber where the catalyst components are maintained in mixture with one another for a desired first contact time. The contents of the third chamber are discharged into a fourth chamber where they are mixed with a third catalyst component for a desired second contact time. The contents of the fourth chamber, comprising the multi-component catalyst system, are then discharged into a reactor where they are contacted with at least one reactant to effect catalysts of the desired chemical reaction within the reactor.