No abstract

Summary: Modeling of fluidized bed reactor for polyethylene production in the condensed mode operation is proposed in this paper. A two-phase model including the emulsion and bubble phases with the constant bubble size is employed to describe hydrodynamic behavior of the reactor. The kinetics of Ziegler-Natta polymerization is also modeled with a two active site model. The phase behavior and solubility of low molecular weight components in polyethylene are estimated with the Sanchez-Lacombe equation of state. The validation of the model is carried out with industrial data for an ethylene and 1-butene copolymerization with the isopentane as a condensable component. The simulation results are in good agreement with industrial data. The model is also used to study quantitatively the effect of the inlet stream temperature to the reactor and isopentane concentration in the reactor on the production rate. For instance, in a typical process, when the inlet stream temperature changes 10 8C, the production rate will alter about 40%. Furthermore, the change of the isopentane concentration around 1 mole percentage leads to a variation of production rate about 14%.

A model is developed for evaluating the performance of industrial-scale gas-phase polyethylene production reactors. This model is able to predict the properties of the produced polymer for both linear low-density and high-density polyethylene grades. A pseudo-homogeneous state was assumed in the fluidized bed reactor based on negligible heat and mass transfer resistances between the bubble and emulsion phases. The nonideal flow pattern in the fluidized bed reactor was described by the tanks-in-series model based on the information obtained in the literature. The kinetic model used in this work allows to predict the properties of the produced polymer. The presented model was compared with the actual data in terms of melt index and density and it was shown that there is a good agreement between the actual and calculated properties of the polymer. New correlations were developed to predict the melt index and density of polyethylene based on the operating conditions of the reactor and composition of the reactants in feed.