Gas Phase Olefin Polymerization Reactor Research Articles

Applied Thermodynamics for Process Modeling in Catalytic Gas Phase Olefin Polymerization Reactors

AbstractThe Sanchez–Lacombe Equation of State (SL EoS) is used to model the solubility of different industrial alkane penetrants in polyethylene to explain the importance of considering different diluents for different processes, and the impact that this choice can have on operating conditions, especially for the production of linear low density polyethylene (LLDPE). Extension of this approach to ternary (ethylene/penetrant/LLDPE) systems shows the effect of composition of penetrant/ethylene mixtures on the solubility of such mixtures in LLDPE and swelling of the polymer phase at conditions of industrial relevance. This analysis reveals that using a constant polymer density instead of that predicted by the SL EoS can result in erroneous calculations of the particle size distribution developments in an olefin polymerization reactor.

Hydrodynamics and particle mixing/segregation measurements in an industrial gas phase olefin polymerization reactor using image processing technique and CFD-PBM model

Particle size distribution (PSD) has a significant impact on the performance of fluidized bed reactors due to uneven distribution in the segregation and mixing phenomena. This paper develops a new method of digital image processing that investigates the hydrodynamics of an industrial gas phase olefin polymerization reactor and studies the fluidization structure of a wide range of particle size distribution in an industrial gas phase polymerization reactor by means of a CFD-PBM coupled model, where the direct quadrature method of moments (DQMOM) was implemented to solve the population balance model. It was shown that the applied parameter assumptions and closure laws were appropriately chosen to satisfactorily predict the available operational data in terms of pressure drop and bed height. The transient CFD-PBM/DQMOM coupled model and image analysis technique are then implemented extensively to analyze bubble fluidization structure and segregation phenomena at different velocities. The particle segregation indicates that the small bubbles present in the bed are unable to induce vigorous mixing at low superficial gas velocity while particle mixing improves at a velocity above the minimum fluidization velocity. Further, the predicted results show higher axial segregation phenomena when compared to the radial direction.

CFD simulation of hydrodynamics and heat transfer in gas phase ethylene polymerization reactors

The hydrodynamics and temperature of a two-dimensional gas–solid fluidized bed of gas phase olefin polymerization reactor had been studied. A two-fluid Eularian Computational Fluid Dynamics (CFD) model with closure relationships according to the kinetic theory of granular flow has been applied in order to simulate the gas–solid flow. Fluidization regime and gas–solid flow pattern were investigated using three different drag models. Model predictions of bed pressure drop were compared with corresponding experimental data reported in the literature to validate the model. The predicted values were in reasonable agreement with the experimental data. The temperature behavior of fluidized bed with various drag models was investigated. The temperature gradient in the primary section of the bed was much larger than the gradient in other sections and the effect of all drag models on temperature gradient along the bed was approximately similar.

Heat Transfer of Polymer Particles in Gas-Phase Polymerization Reactors

In this paper the effects of particles configuration and particles distance on the heat transfer rate in a gas phase olefin polymerization reactor have been studied using the computational fluid dynamic (CFD) modeling approach. The goal was to determine the causes of particle overheating in this reactor. It has been shown that classic correlations such as Ranz-Marshall are sufficiently adequate when far away particles with no interactions are to be modeled. However, when particles are sufficiently close to having interactions, these correlations fail to satisfactorily predict the convective heat transfer coefficient. The results indicate an increase in particle distance leads to an increase in the Nusselt number on the particle surface. Therefore, for particles with a large distance and triangular or rotated square configurations, the local Nusselt number is closer to the Nusselt number for a single particle.

Modeling of particle segregation phenomena in a gas phase fluidized bed olefin polymerization reactor

In a gas phase fluidized bed olefin polymerization reactor, it is generally assumed that polymer particles are well mixed and near isothermal reaction conditions prevail. When a highly active Ziegler–Natta catalyst or other type of high activity supported catalyst is used in a gas phase fluidized bed reactor, a certain heterogeneity in the polymer properties is often observed in different size particles. Moreover, particle agglomeration and sheeting phenomena may also occur due to irregular particle growth, internal particle segregation or nonisothermal effect. In many of the past reports, particle residence time distribution has been commonly used as a tool to calculate polymer particle size distribution in a fluidized bed polyolefin reactor. In this paper, a multi-compartment population balance model is presented to directly model the particle segregation phenomena and particle size distribution in a gas phase olefin polymerization reactor. To model the particle segregation effects, size dependent particle transfer constants are employed. The effects of various fluidized bed operating conditions on the particle size distribution are investigated through model simulations.

Population balance modeling for a continuous gas phase olefin polymerization reactor

AbstractSteady‐state population balance models have been developed for a continuous flow gas phase olefin polymerization process with both uniform sized and log‐normally size distributed high activity catalyst feeds. For the calculation of polymer properties such as molecular weight averages and weight fraction of comonomers in the copolymer, a multigrain solid core model was used with an assumption that intraparticle monomer mass transfer resistance is negligibly small. The multigrain solid core model was incorporated into the population balance model and the effects of feed catalyst particle size distribution and catalyst deactivation parameters on the polymer production rate, polymer particle size distribution, and polymer properties were investigated. It is observed for deactivating catalyst that the polymer particle size distribution tends to be narrower with a reduced amount of large polymer particles. For the catalyst with nonuniform site deactivation, polymer particles of different sizes exhibit different molecular weight and copolymer composition. © 1994 John Wiley & Sons, Inc.