Multiscale modelling of multizone gas phase propylene (co)polymerization reactors—A comprehensive review

Abstract Catalysts and polymerization processes have evolved over the years. Such significant developments have allowed producers to broaden the range of polymer microstructure and process productivity, thereby making it possible to offer a wide range of end‐use properties at a reasonably low cost. However, these advantages in catalyst performance and reactor operation require that we understand as much as possible about reactor operation in the broadest sense. In addition to the fundamental experimental study of polymer chemistry, this means that one needs to develop complete, robust process models. The present paper provides a rapid overview of recent developments in various gas phase propylene (co)polymerization reactors in use today, concentrating on multizone gas phase polypropylene reactors: that is, multizone circulating reactor, fluidized bed reactor with internal circulation, fluidized bed reactor with external circulation, and horizontal stirred bed reactor. We then concentrate on the advances in multiscale modelling of gas phase propylene (co)polymerization reactors, from microscale kinetics at the active sites, to the mesoscale, including physical transport and thermodynamic modelling at the single‐particle level and its boundary layer, up to the macroscale reactor modelling. A systematic guideline used for the selection of appropriate thermodynamic models is proposed for gas phase olefin polymerization processes. Finally, current challenges and remaining issues related with the development of mathematical multiscale modelling are addressed.