Yield Prediction in a Continuous High-Density Polyethylene Solution Polymerization Staged Reaction Process System

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The catalyst behavior in a continuous polyethylene polymerization train is of utmost importance in the economic performance of a high-density polyethylene (HDPE) unit. A mathematical model was developed to predict polymer catalyst yield in the HDPE solution polymerization as a function of the processing conditions in the reactor train, catalyst deactivation kinetics, the reactors' flow characteristics, and the residence time distribution. A very large plant data set was used to perform nonlinear model parameter estimation and to compare the model predictions to measured polymer yield in the plant. Several models were tested, and correlation coefficients r2 as high as 0.91 were obtained.