A segregation–backmixing
model is developed to simulate
the dynamic operation of multifeed high-pressure low-density polyethylene
(LDPE) autoclaves, calculate the specific initiator consumption (grams
of initiator per kilogram of LDPE), and assess the risk of ethylene
decomposition under different nonideal mixing and operating scenarios.
To describe the nonideal macro- and micromixing phenomena in a LDPE
autoclave, a user-specified multizone model representation of the
actual reactor is established. One of the key features of the present
model is that the continuously fed initiator into a reaction zone
can exhibit two distinct states, namely, a “segregated”
or a “molecular” one. Simulation results are presented,
showing the effects of macro- and micromixing model parameters on
the spatial temperature distribution and specific initiator consumption
with respect to the initiator feed concentration to a two-compartment
reaction zone. Finally, the operational conditions and process faults
that can lead to ethylene decomposition in a reaction zone are investigated.