This work presents an exhaustive mathematical model for the high pressure polymerization of ethylene in tubular reactors of configuration sim1lar to that encountered in the industry. Multiple injection of monomer, mixtures of initiators and chain transfer agents are considered together with realistic flux configurations. Typical heat transfer coefficients are estimated from industrial plant data. The effects of pressure pulse on the reactor behavior are also analyzed. Instantaneous temperature profiles produced by such pressure pulse were recovered from stationary simulations showing a very good agreement with the corresponding experimental data . The model features are demonstrated by predictions of temperature, concentrations of reactants and products and molecular properties as a function of reactor length. Also, appropriate predictive capabilities are d1sclosed by comparison of model simulation results and experimental data. The generation of a high temperature initiator, derived from oxygen, is assessed by comparison of temperature profiles corresponding to runs with and without oxygen.

We present a method for the adjustment of parameters in the mathematical modeling of industrial tubular reactors for high pressure polymerization of ethylene. We propose a reduced mathematical model for these reactors that aids in the task of model parameter update commonly done periodically in industrial plants. This reduced model was built from a detailed model for multiple peroxide and oxygen initiator systems we had developed before. Some of the assumptions in that rigorous model were reviewed in order to minimize computational effort. Good and faster predictions were obtained by assuming different constant jacket temperatures and pressures at each zone. Pressure pulse equations had to be included in the model. A simplification of the adjustment procedure is also proposed here. It consists in using only the reactions considered crucial for the description of this polymerization. The peroxide initiator and solvent mixtures were treated as fictitious unique initiator and solvent respectively. A procedure was established for the quick estimation of the kinetic parameters that represent initiator and solvent mixtures of different compositions. This resulted in a model that can be adjusted rapidly to predict the behavior of a specific industrial reactor. The reduced model was validated using experimental runs initiated by oxygen either alone or together with peroxide mixtures.

Heat transfer in tubular reactors for the high pressure polymerization of ethylene is very complex, since these tubular reactors are usually divided into several zones that exhibit different flow patterns and critical fouling behavior. The correct estimation of the overall heat transfer coefficient along the reactor axial distance is a major issue when assessing the predictive capabilities of a mathematical model for the process. In general, previous models employed either constant heat transfer coefficients or the usual correlations for the Nusselt number. Neither of these two approaches is accurate enough to allow a correct prediction of the reactor behavior with respect to temperature profiles and product molecular properties. The present work performs a more comprehensive estimation of the heat transfer coefficient in these reactors. At a first stage the overall heat transfer coefficients were estimated by using appropriate energy balances and a good set of experimental data. Then, a predictive model was proposed for the overall heat transfer coefficient. All flow regimes, as well as fouling effects, were taken into account, and the parameter estimation was based on temperature profiles obtained from an industrial reactor. The temperature profiles, conversions, pressures and molecular properties calculated by means of the experimentally fitted heat transfer coefficients or with the predictive model showed good agreement with plant data.tally fitted U m a y be inadequate for the simulation of