Transient Behavior and Control of Polyethylene Production in a Fluidized Bed Reactor Utilizing Population Balance Model

In this study, a fluidized bed reactor for polyethylene production was employed using a dry mode approach, where the recycle stream may contain components of a nature that cannot be condensed through standard cooling. To analyze the behavior of the fluidized bed reactors during the copolymerization of ethylene with butene, a dynamic population balance model was employed. The study includes sensitivity analyses through computer simulations to examine the variations in reactor temperature, molecular weights, catalyst feed rate, and monomer/comonomer concentrations in the fluidized bed reactor. It is noteworthy that the reactor exhibits instability under normal operational conditions and is sensitive to changes in the catalyst feed rate and coolant temperature of the heat exchanger. The findings also highlight challenges such as temperature fluctuations above the polymer melting point. This underscores the importance of implementing a temperature control system to prevent issues like reactor shutdown due to elevated temperatures. Dynamic instabilities were observed under specific circumstances and were successfully controlled using Proportional Integral Derivative (PID) control strategies. The population balance model is essential for understanding the complexity of transient polymerization reactions. It enables researchers to simulate and optimize polymerization processes by utilizing the detailed kinetics of the reaction.

Modeling Sorption of Hydrocarbons in Polyethylene with the SAFT-γ Mie Approach Combined with a Statistical-Mechanical Model to Describe Semicrystalline Polymers

A recently developed statistical-mechanical model is applied systematically to estimate the fraction of tie-molecules (polymer chains linking different crystals directly or via entanglements) in semicrystalline polyethylene (PE) samples. The amorphous domains of the polymer are divided into constrained interlamellar domains and "free" outer-lamellar domains. A set of model parameters is assigned to each sample by correlating previous experimental measurements and minimizing the difference between the predicted solubility of pure hydrocarbons in the sample and the experimental values. We show that the sorption isotherms of multiple pure fluids in each sample can be described by a single parameter set, proving that the polymer-solute interactions (described accurately by the SAFT-γ Mie EoS) are decoupled from the sample-specific properties of the polymer. We find that ∼30% of the crystalline stems in the lamellae of PE are connected to tie-molecules, within the bounds suggested by previous theoretical and computational work. The transferability of the sample-specific parameters is assessed by predicting cosolubility effects and solubility at different temperatures, leading to good agreement with experimental data.