Patent No. EP3592780 (titled "Process For Producing Polyethylene Polymers") was filed by Exxonmobil Chemical Patents on Feb 7, 2018. The application was issued on Jul 23, 2025.
A gas phase polymerization process produces polyethylene polymers with a density less than 0.940 g/cc by contacting ethylene and at least one C3 to C8 alpha-olefin comonomer with a polymerization catalyst on a particulate support within a fluidized bed reactor. The bed, comprising growing polymer particles, formed polymer particles, and catalyst particles, is fluidized by a continuous flow of make-up feed and recycle gas. The particulate support is characterized by laser diffraction particle sizes of d10 $\ge$ 18 $\mu$m, d50 $\ge$ 40 $\mu$m, and d90 $\le$ 100 $\mu$m. This specific support size distribution reduces polymer fines, thereby minimizing entrainment, sheeting, and fouling of reactor components, which enables higher superficial gas velocities and increased production rates.

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