Mathematical modeling of olefin polymerization processes has advanced significantly, driven by factors such as the need for higher-quality end products and more environmentally-friendly processes. The modeling studies have had a wide scope, from reactant and catalyst characterization and polymer synthesis to model validation with plant data. This article reviews mathematical models developed for olefin polymerization processes. Coordination and free-radical mechanisms occurring in different types of reactors, such as fluidized bed reactor (FBR), horizontal-stirred-bed reactor (HSBR), vertical-stirred-bed reactor (VSBR), and tubular reactor are reviewed. A guideline for the development of mathematical models of gas-phase olefin polymerization processes is presented.

Dynamic modeling of the polyolefin polymerization process in the gas phase is relatively complex due to its high nonlinearity. This nonlinearity is induced by several factors including the reaction mechanism, the heat and mass transfer mechanism, the flow properties in both solid and gas phases, the type of reactor, and the correlations between the operating conditions and the chemical and physical properties of the polyolefin. In this study, polymerization of the polypropylene was observed in a fluidized bed reactor to potentially improve the solid elutriation correlations proposed previously, to increase the reliability and the accuracy of this two-phase model. By embedding the improved solid elutriation correlations, the production rate was reduced relative to earlier proposed solid elutriation correlations due to the loss of the product at the top of the fluidized bed reactor. The composition of the reactants and the catalyst flow rate also influenced the production rate, yet the inlet temperature did not.The current two-phase model is validated with the pilot plant data with the deviations lower than the previously validated model with reference to the production rate, the concentration of propylene and hydrogen, and the temperature of the reactor. K E Y W O R D Sfluidized bed reactor, gas phase, polyolefin, propylene, solid elutriation, two-phase model

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