Predictive two-phase modeling and improvement for industrial UnipolⓇ polypropylene process – Development and a case study

This work presents a two-phase model describing propylene catalytic polymerization for UnipolⓇ technology with a fluidized bed reactor (FBR) using Aspen PlusⓇ software and the sequential modular simulation approach. The hydrodynamic aspects of the FBR were incorporated to provide better realism in describing the performance of the FBR. A detailed kinetic multi-site model for polymerization reactions occurring inside the FBR was proposed. Industrial data from a UnipolⓇ plant during normal operation were used to calibrate the model parameters. Obtained data sets were tested and screened to confirm data validity for establishing the model and averting incorrect outcomes. The model was validated against different industrial data and then was used to investigate the influences of different process variables on the plant's performance. Finally, the model was used to improve the process illustrating a prospective for remarkable savings in energy consumption in the process while enhancing the plant throughput.