Continuous soluble Ziegler-Natta ethylene polymerizations in reactor trains, 3 - Influence of operating conditions upon process performance

Abstract

The behavior of continuous solution ethylene/but-1-ene polymerizations through Ziegler-Natta catalysts is analyzed, based on a previously developed mathematical model. In order to do that, dynamic simulations are carried out and process responses are analyzed as functions of process operating policies and flowsheet configuration, at conditions that resemble the actual operation of industrial sites. It is shown that system responses are highly nonlinear and very sensitive to disturbances of the operating conditions and that catalyst decay is of fundamental importance for proper understanding of process behavior. Results indicate that mixing conditions inside the reactor vessels exert a significant impact upon the final polymer quality and can be manipulated for in-line control of final resin properties. Finally, it is shown that the development of feed policies, based on the use of lateral feed streams, allows the simultaneous control of melt flow index, stress exponent and polymer density of the final polymer resin.