A comprehensive dynamic model for high-pressure tubular low-density polyethylene (LDPE) reactors

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2006-01-01
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Boopathy, Mothivel
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Rodney O. Fox
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Chemical and Biological Engineering

The function of the Department of Chemical and Biological Engineering has been to prepare students for the study and application of chemistry in industry. This focus has included preparation for employment in various industries as well as the development, design, and operation of equipment and processes within industry.Through the CBE Department, Iowa State University is nationally recognized for its initiatives in bioinformatics, biomaterials, bioproducts, metabolic/tissue engineering, multiphase computational fluid dynamics, advanced polymeric materials and nanostructured materials.

History
The Department of Chemical Engineering was founded in 1913 under the Department of Physics and Illuminating Engineering. From 1915 to 1931 it was jointly administered by the Divisions of Industrial Science and Engineering, and from 1931 onward it has been under the Division/College of Engineering. In 1928 it merged with Mining Engineering, and from 1973–1979 it merged with Nuclear Engineering. It became Chemical and Biological Engineering in 2005.

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1913 - present

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  • Department of Chemical Engineering (1913–1928)
  • Department of Chemical and Mining Engineering (1928–1957)
  • Department of Chemical Engineering (1957–1973, 1979–2005)
    • Department of Chemical and Biological Engineering (2005–present)

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Chemical and Biological Engineering
Abstract

Low-density polyethylene (LDPE) is a versatile polymer which is widely used both in domestic and industrial applications. About 50% of commercial LDPE production around the world is carried out by free-radical polymerization initiated by organic peroxides in high-pressure tubular reactors. The free-radical polymerization is highly sensitive to even small changes in process conditions. As a result, the extreme pressures and temperatures in the high-pressure tubular LDPE reactor (HPTLR) present operational challenges to the plant engineer. A reliable model of the HPTLR will prove to be a valuable tool for the plant engineer in making decisions about reactor operations;In this work, a comprehensive dynamic model for the HPTLR has been developed for the prediction of reactor behavior. The model combines the power of CFD (computational fluid dynamics)-based modeling with the simplicity and intuition of CRE (chemical reaction engineering)-based micromixing models. The mathematical model is based on the finite-mode PDF (probability density function) approach to modeling turbulent reactive flows. The advantage of this approach is that the source terms in the model transport equations appear in closed form thus obviating the need for closure approximations which are common in (and the main shortcoming of) CRE-based reactor models. Some simplifying assumptions (which are found to be true in most cases of HPTLR operations) have been made, important among which is the assumption of fully-developed turbulent pipe flow. A two-environment model is used to describe micromixing. Free-radical mechanisms are considered for both LDPE polymerization reactions as well as ethylene decomposition reactions. Heat-transfer effects between the reactor tube and the coolant water jacket surrounding it are also considered. The resultant transport equations, which are convection-diffusion-reaction (CDR) - type partial differential equations, are numerically solved using a fractional time-stepping method;Model parameters have been estimated using plant data for both steady-state and dynamic behavior. Using experimental design techniques, the most influential parameters in the model have been determined. Dynamic behavior of the model under typical reactor operating conditions was studied. From our studies, we conclude that our model should prove to be an effective tool for the plant engineer in making critical plant-operation decisions.

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Sun Jan 01 00:00:00 UTC 2006