Polymerisation of Ethylene · in Slurry Loop Reactors by Allemeersch, Paul -- Read -- Imperial Library of Trantor

Index

Also of Interest Title Page Copyright Page Preface Table of Contents 1 Introduction to the Slurry Loop Process 2 The Loop Reactor Circulation Pump Power

2.1 Reactor Pump Circulating Pure Liquid 2.2 Reactor Pump Circulating the Slurry 2.3 Upsets in Reactor Pump Power

2.3.1 A Realistic Reactor Pump Power Curve 2.3.2 Reactor Fouling 2.3.3 Hot Spots

2.3.3.1 Conditions at which a Hot Spot is Created 2.3.3.2 Interpretation of the Integers m and k 2.3.3.3 Margins to be Respected around m/k Values

Notations

3 The Functioning of the Settling Legs

3.1 The Functioning of the Settling Legs

3.1.1 Description and Definitions 3.1.2 The Overall Reactor Mass Balance 3.1.3 The Volumetric Output Equation 3.1.4 The Solids Removal Rate Equation

3.2 Correlations for the Effective Settling Velocity

3.2.1 General Correlation 3.2.2 Specific Correlations 3.2.3 Correlation with the Terminal Falling Velocity

3.3 Control of the Solids Concentration in the Loop Reactor

3.3.1 The Solids Concentration Control Equation 3.3.2 Control of the Solids Concentration 3.3.3 Stability of the Solids Concentration Control

Notations

4 The Settling of the Polymer in the Settling Legs

4.1 Description and Definitions 4.2 Kynch’s Sedimentation Theory 4.3 Growth Rate of the Zone of Thickened Slurry 4.4 Settling Behaviour of the Polymer 4.5 Maximum Filled Fraction of the Settling Legs 4.6 Settling Legs with a Change in Diameter Notations

5 Catalyst Activity and Productivity

5.1 The Polymerisation Reaction 5.2 Polymerisation Rate Equation 5.3 Catalyst Activity 5.4 Catalyst Reactor Productivity 5.5 Catalyst Reactor Productivity in a Batch Reactor Notations

6 The 1/1 Hypothesis

6.1 Silica Particles 6.2 Catalyst Particle Fragmentation and Growth 6.3 Catalyst Particle Productivity 6.4 Balance for the Number of Particles 6.5 Verification of the 1/1 Hypothesis Notations

7 Catalyst Residence Time Distribution

7.1 Definitions and Assumptions 7.2 Perfect Mixing of the Catalyst 7.3 Catalyst Activity 7.4 Catalyst Reactor Productivity 7.5 Mass of Polymer Present in the Reactor 7.6 Catalyst Residence Time Distribution 7.7 Mass Balance for the Polymer 7.8 Experimental Measurement of the Catalyst Residence Time Distribution in the Loop Reactor

7.8.1 Cumulative RTD and Response to a Step Signal 7.8.2 Experiment

Notations

8 Catalyst Activity Profiles from Full Scale Loop Data

8.1 Calculating the Catalyst Activity Profile from Full Scale Loop Data 8.2 Catalyst Productivity Curve and Activity Profile in the Loop Reactor 8.3 Catalyst Particle Productivity 8.4 Experimental Results for Catalyst Activity Profiles from Full Scale Data 8.5 Catalyst Activity Profiles Showing an Induction Time Notations

9 Conversions of the Reactants

9.1 Calculating Conversions from Full Scale Reactor Data 9.2 The Conversion of Ethylene 9.3 The Conversion of Hydrogen

9.3.1 Hydrogen to Ethylene Ratios 9.3.2 Calculating the Hydrogen Conversion

9.4 The Conversion of 1-Hexene

9.4.1 1-Hexene to Ethylene Ratios 9.4.2 Calculating the 1-Hexene Conversion

9.5 Conversions and Polymer Properties

9.5.1 Correlations for Melt Index 9.5.2 Incorporated 1-Hexene and Density

9.6 In-situ Generation of 1-Hexene with CrOx Catalysts 9.7 Optimisation of Reactor Conditions Based on Conversions Notations

10 The Ethylene Concentration Profile in the LoopReactor

10.1 Reactor Geometry 10.2 Slurry Flow in the Reactor 10.3 Catalyst Activity 10.4 Rate of Reaction along the Loop 10.5 Ethylene Concentration Profile in the Loop 10.6 Increasing Production Rates in the Loop Reactor Notations

11 A Simple Model for the Slurry Loop Reactor

11.1 Elements to Build the Model with

11.1.1 Overview of the Variables 11.1.2 Independent Variables 11.1.3 Dependent Variables 11.1.4 The Use of Conversions

11.2 Simplifying Assumptions 11.3 Mathematical Relations

11.3.1 Polymer Properties 11.3.2 Conversions 11.3.3 Physical Properties 11.3.4 Catalyst Activity 11.3.5 Flash Gas Flows 11.3.6 Reactor Feeds 11.3.7 Constraints

11.4 A Corrective Off-line Model Notations

12 Establishing Correlations from Loop Reactor Data by Linear Regression

12.1 The Data Set 12.2 Building the Data Set 12.3 Establishing the Correlations

12.3.1 Inspection of the Data Set 12.3.2 Inspection of the Observations by Cluster Analysis 12.3.3 Inspection of the Pearson Correlation Coefficients between the Variables 12.3.4 Establishing the Correlation by Linear Regression

Notations

13Scaling-Up from Bench Reactor to Loop Reactor

13.1 Bench Reactor Polymerisation Tests 13.2 Variables in Bench Reactor Polymerisation Tests 13.3 Catalyst Activity 13.4 Data Set and Correlations 13.5 Translating Bench Scale Variables into Loop Reactor Conditions

13.5.1 Type and Composition of the Catalyst 13.5.2 Ethylene Concentration 13.5.3 Reactor Temperature 13.5.4 Catalyst Activation Temperature 13.5.5 Hydrogen Concentration 13.5.6 Comonomer Concentration 13.5.7 Dosage of the Cocatalyst 13.5.8 Comparing Bench Results to Full Scale Loop Data

13.6 Molecular Weight Distributions from Bench Scale Tests Notations

14 The Operation of Two Loop Reactors in Series

14.1 Mass of Polymer Present in the Second Reactor 14.2 Catalyst Residence Time Distribution in the Second Loop Reactor 14.3 Total Catalyst Residence Time Distribution in Two Loop Reactors in Series

14.4 Assumed Catalyst Productivity in a Second Loop Reactor in Series

14.5 The Bimodality Distribution for Two Loop Reactors in Series

14.5.1 The Ideal Bimodality Distribution 14.5.2 A Realistic Bimodality Distribution

Notations

Index

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