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International Journal of Applied Engineering Research ISSN 0973-4562 Volume 11, Number 19 (2016) pp.

9906-9913
© Research India Publications. http://www.ripublication.com

Low Density Polyethylene Tubular Reactor Modeling: Overview of the


Model Developments and Future Directions

A. Azmi N. Aziz,
PG Scholar, Associate Professor,
School of Chemical Engineering, School of Chemical Engineering,
Universiti Sains Malaysia, Nibong Tebal, Universiti Sains Malaysia, Nibong Tebal,
14300, Penang, Malaysia 14300, Penang, Malaysia

Abstract high-pressure LDPE tubular reactor consists of a spiral-


Low-density polyethylene (LDPE) is one of the most widely used wrapped jacketed metallic pipe with the total length of the
polymers in the world. Commercially a very flexible and tube ranges from 500 to 1500 m arranged as a series of
branched LDPE is produced through free radical polymerization straight sections connected by 180 degree bends, whereas the
of ethylene (monomer), in the presence of chemical initiators (i.e., inner diameter does not exceed 60-80 mm [1,3]. Wall
peroxides, oxygen, azo compounds) in high pressure long tubular thickness equivalent to inner diameter is used to provide
reactor. A single polyolefin plant producing thirty to forty grades necessary strength for the high-pressure involved in
of polymer, therefore understanding the reaction mechanism, the polymerization of ethylene, typically at pressures of 101325
operating variables as well as the dynamic behavior of tubular –303975 kPa and temperatures of 373.15 – 598.15 K [1].
reactor is essential. Furthermore, as the LDPE industry becomes Schematic diagram of an industrial LDPE tubular reactor is
more competitive, manufacturers have to cope with growing shown in Figure 1. In Figure 1, TJin,n are the jacket inlet
pressures for production cost reductions and more stringent temperature whereas TJout,n are referred as jacket outlet
polymer quality requirements. To accomplish these goals, for the temperature.
past forty years numerous researchers had developed various With regards to the process heat prerequisite, the
computational and mathematical models capable of monitoring, tubular reactor is segregated into a number of zones namely
predicting, optimizing and controlling the polymerization process preheating, reaction, and coolant zones. A typical commercial
of polyethylene. The present paper provides an overview of the tubular reactor usually comprise of 2 – 6 reactor zones and 6
model developments and its recent progress. It also addresses the – 12 coolant zones as shown in Figure 1, depends on the
conceptual ideas for future improvement work in LDPE tubular reactor design and product specifications. In the initial zone,
reactor modeling. Ethylene with other feed stream is heated (by steam or water)
up to the optimal temperature at which the polymerization is
Keywords: Tubular reactor, LDPE, Polymerization, Modeling. initiated via the thermal decomposition of initiators. This
temperature relies on initiator utilized, ranging from 463.15
K for oxygen to 413.15 K for a peroxy-dicarbonate [4].
INTRODUCTION Ethylene polymerization is a highly exothermic reaction. The
Low-density polyethylene (LDPE) is one of the most important heat generated during polymerization reaction is partially
polymers with great industrial significance. LDPE constitute large removed through the reactor wall by the heat-transfer fluid,
number of applications including packaging, adhesives, coatings which flows inside a reactor jacket. Almost half of the heat
and films. Being a commodity polymer, LDPE consumption generated via the reaction is removed by the cooling fluid
accounts for the 40% of worldwide polyethylene, which reached flowing in the reactor jacket co- or counter currently to the
over 35 million metric tonnes in 1994, and has been reported to reaction fluid [3].
increase rapidly at the rate of 7% per year over the past 15 years
[1,2]. The exclusive properties of LDPE and its copolymers Table 1. Properties of commercial LDPE [5]
indicate that the demand for these precious polymer grades will
remain enthralling in the near future. Driven by commercial Property Range
interest and improvement opportunity, numerous articles have 3
been published about its physical properties, reaction mechanisms Density (kg/m ) 910 - 940
and process simulation and optimization. Melting temperature (K) 371.15 - 388.15
A very flexible and branched LDPE, typically in the range of 910 Melt flow index (g/10min.) 0.2-50
– 940 kg/m3 manufactured commercially in a high-pressure free Tensile modulus (Mpa) 172.37 – 344.74
radical polymerization reactors in the presence of a mixture of Tensile yield stress (Mpa) 8.96 – 19.31
initiators (e.g., peroxides, oxygen and azo compounds). Table 1
lists the property-ranges for commercial LDPE varieties. The industrial significance of high-pressure LDPE tubular
Practically, almost all low-density polyethylene (LDPE) is reactor technology has led to extensive studies on reactor
manufactured in stirred autoclaves or in tubular reactors at high modeling over the past 40 years. The most important goal of
pressures. This paper focuses primarily on tubular reactor. The the research is the maximization of the production
high pressure tubular reactor is characterized by very large ratios (maximization of the monomer conversion for a given feed
of length to diameter (L/D) ranging from 1 – 6 × 10-4. A typical

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International Journal of Applied Engineering Research ISSN 0973-4562 Volume 11, Number 19 (2016) pp. 9906-9913
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flow rate) and minimization of unwanted product (ethyl, butyl, REACTION MECHANISM AND KINETICS
vinyl and vinylidene groups), while maintaining the A lot of extensive studies have been done on the reaction
polymer product quality with regards to its molecular weight mechanism and kinetics of free-radical ethylene
distribution (MWD). The typical monomer conversions in tubular polymerization. The reaction mechanism applied give
reactor is reported to be vary in the range of 20-35% per pass significant effect to the reaction temperature profiles and
[3,4]. This paper presents the review of the model developments polymer properties. To date, no reaction mechanism is fixed
and its recent progress in terms of reaction kinetics and reactor in the various literatures published. There are no mutual
modelling, simulation, and optimization. agreement between authors to make the reaction mechanism
fixed for their modelling. The only reaction that is
completely acceptable for all authors are the main reaction of
free-radical polymerization which are initiation of free-
radicals, propagation and termination. In general, there are
more than 10 reaction mechanism (besides the main reaction)
available in the literatures in which researcher is open to
include or exclude in their model. Table 2 illustrate the
availability of particular reaction mechanism in several
papers available in the literature.

Fig.1. Schematic diagram of an industrial LDPE tubular reactor


[6]

Table 2. Summary of reaction mechanism availability in the recent publication.


Authors
Reaction mechanism
Asteasuain and Meimaroglou Disli and Erdeghem et al.
Brandolin [7] et al. [26] Kienle [29] [23]
Main reaction:
Oxygen Initiation √ x x x
Peroxide Initiation (decomposition) √ √ √ √
Monomer thermal initiation √ x √ x
Generation of inert √ x x x
Propagation √ √ √ √
Termination by Combination √ √ √ √
Termination by disproportionation x √ √ √
Termination by thermal degradation √ x x x
Side Reaction:
Chain transfer to polymer √ √ √ √
Chain transfer to monomer √ √ √ √
Chain transfer to solvent √ √ √ √
Backbiting √ √ √ √
β-Scission of secondary radical √ x x x
β-Scission of tertiary radical √ x x x
β-Scission or random scission x √ √ √

To date, reaction mechanism applied in Asetasuain and Brandolin Peroxide initiation mechanism is unanimously accepted
[7] can be considered as the most accomplish reaction among researchers in this field. However the latter initiation
mechanism. Most of the reactions were selected after reviewing mechanism which are oxygen and monomer thermal
the works by numerous publications initiation have thus fail to gain mutual agreement among
[8,9,10,11,12,13,14,15,16,17,18]. The generation of free radicals researchers. In the early LDPE industrial process, oxygen
is called initiation. Oxygen (O2) and organic peroxide (I) was used as initiator due to its ease of feeding into the
initiation, and monomer (M) thermal initiationgenerate free reactor. However, as time pass by, through the developments
radicals when the reactor temperature reaches appropriate levels. of high-pressure pumps and compressors, new plants employ

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International Journal of Applied Engineering Research ISSN 0973-4562 Volume 11, Number 19 (2016) pp. 9906-9913
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solutions of liquid catalyst as initiator. A part from that, solutions Thus far, almost all researchers have included this
of liquid catalyst commonly organic peroxide help to ensure the mechanism (chain transfer to monomer, polymer and solvent)
precise control of temperature profiles inside the reactor. in their model except few, notably Chen et al. [9] due to
Some researchers [1,3,9,19,20,21,22,23] have neglected the model simplification purpose.
oxygen initiation mechanism due to the fact that the mechanism Backbiting reaction and scission reactions is the major source
by which oxygen generates the free radicals is complicated and of short chain branching (SCB) in LDPE and they were
not well understood [4]. A part from that, it can acts as inhibitor selected after reviewing the works of Goto et al. [11]. The
to radical polymerization at lower temperature. It reacts with backbiting reaction, occurs when the carbon atom preceded
carbon radicals (both primary and chain), leads to the formation by four carbons back down the chain. Agrawal et al. [4]
of peroxy-radicals, which are relatively unreactive [24]. However, conclude that these branches contain entirely ethyl- and
Agrawal et al. [4] stated that oxygen is still widely used, either butyl- groups. β-Scission of secondary and tertiary radical
alone or sometimes in combination with liquid initiators in the allow the independent estimation of the short chain branching
tubular reactor process. The consideration of oxygen initiation such as vinyl and vinylidene groups. Nevertheless, for
mechanism in Brandolin et al. [18] model is based on the works several authors [23,26,29], they considered the scission
by Tatsukami et al. [11], Hollard and Ehlrich [12] and Brandolin reaction to be in random, rather than separately as was used
[13]. In general, at low concentration, oxygen may act as an in Asetasuain and Brandolin [7]. Selection of reaction
indirect initiator, where oxygen first reacts with monomer to form mechanisms plays significant role to develop an accomplish
peroxides. These peroxides then decompose and actively react model with highest accuracy. However, depending on the
with monomer to generate chain radicals which initiate the degree and complexity of the research scope, one has the
polymerization [24]. Tatsukami et al. [11] postulated the reactions options of including or excluding the reaction mechanism
which account for initiation and inhibition effects of oxygen component in their model based on the justification
would help to predict the shape of the temperature profile at the mentioned in literatures.
peak and therefore increase the accuracy of the model.
Kim and Iedema [21] have removed monomer thermal initiation
due to the fact that the reaction is a slow third order reaction in MODELLING, SIMULATION AND OPTIMIZATION
the absence of initiators thus it is negligible in their modelling. Extensive workers (engineers, researchers and chemist) have
Other authors [9,13,23,25,26] removed it from their model due to sought to model the high pressure low density LDPE tubular
simplification purpose. However, Asteasuain et al. [27] stressed reactor over the past few decades. However, even with the
that monomer thermal initiation must necessarily be kept in extensive works of research, complete understanding of the
reaction mechanism because it becomes important at runaway physico-chemical phenomena occurring inside such reactors
conditions in the tubular reactor, which occurs at higher still remains elusive. This section review some of the
temperature. The free radicals react with monomer to produce a previous study carried out by previous researchers. A
growing macromolecule during propagation and increase the complete review of all research is extremely huge and
chain length. This macro radicals may be deactivated by oxygen, beyond our capability and we have attempted here to
generating an inert. Asteausuain and Brandolin [7] stressed the highlight key efforts relevant to LDPE study. A
significance of this reaction in order to obtain an accurate comprehensive study has been carried out on modeling of
prediction of temperature peaks. Natural termination is obtained LDPE process [1,4,7,9,10,16,18,23,30,31,32,33]
by combination of growing radicals react with each other and In most of the studies, homogeneous phase (single phase) of
form dead polymers or via thermal degradation. Ehrlich and ethylene and polyethylene is assumed. Ehrlich and Mortimer
Mortimer [8], Chen et al. [9] and Brandolin et al. [13] reject the [8] studied the phase-equlibria and the elementary reactions
idea to include mutual chain termination by disproportionation in involved in the free-radical polymerization of ethylene. One
their model since they identify that the inclusion of this reaction of the important findings of their research is that, at typical
will serve no purpose. temperatures and pressures encountered in commercial
Chain transfer to monomer and polymer, and the use of non- polymerization processes, the monomer and polymer, form
saturated solvents (S) such as propylene, allows for the generation and exists as a single fluid phase. This fact has been used in
of polymer and initiation radicals possessing terminal double many subsequent modeling studies. Further study by Buback
bonds. Such form may propagate and favor the long chain [16] in an extended pressure and temperature region above
branching occurrence [18]. Adding transfer agents or solvents (S) 150 Mpa and 423.15 K, reveal that the reaction mixture
to the tubular reactor help to control the molecular weight, since inside reactor exists as single phase respectively. Following
they react with radicals producing a dead polymer and initiation this Zabisky et al. [32] used this assumption on their terminal
radical. Such reactions occur through hydrogen abstraction and model for copolymerization.
consequently lead to shorter macromolecules. Transfer to Agrawal and Han [30] performed a modelling study with
monomer and polymer are also crucial for the prediction of the axial mixing to determine its effect on the LDPE tubular
molecular weights. Agrawal et al. [4] stated in their paper that reactor performance. This research was the first of its kind
chain transfer to monomer is small in case of ethylene and the since earlier efforts at modeling LDPE tubular reactors have
reaction is quite similar to other monomer systems as well. In considered plug-flow in their models. They stressed that axial
case of chain transfer to polymer, Pladis and Kiparissides [28] mixing in such reactors is of significance due to the pulse
concluded that it is the primary reaction in the formation of long valve effect inside the tubular reactor. Latter study carried by
chain branches (LCB). In high pressure ethylene polymerization, Chen et al. [9] which utilized on a simplified plug-flow
these branches widen the molecular weight distribution of LDPE.

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Table 3. Rate constant from different researchers

Rate Chen et al. [9] Mavridis and Kiparissides Brandolin et al. [18]
constant [36]
A (1/s) E (kJ/mol) A (1/s) E (kJ/mol) A (1/s) E (kJ/mol)
1.60E16 160.66 2.50E14 125.52 1.1E10 – 8.7E17 94.56 – 133.05
- - 5.93E18 195.21 1.1E10 – 3.2E13 94.56 – 132.63
- - - - (1.60 ± 0.0010)E11 135.85 ± 0.02
- - - - - -
2.95E7 29.67 1.25E8 31.04 (4.0 ± 0.0110)E5 17.61 ± 0.003
1.60e9 10.04 2.50E9 4.18 (8.7 ± 0.0130)E8 15.27 ± 0.003
- - 2.50E9 4.18 - -
2.72E11 83.68 - - - -
- - 1.25E6 45.35 (1.2 ± 0.0001)E5 60.25 ± 0.004
9.00E5 37.66 1.24E6 30.33 (7.6 ± 0.0006)E9 79.91 ± 0.006
- - 2.75E7 43.39 4.6E6 – 9.9E7 33.05 – 46.86
- - - - (1.2 ± 0.0002)E10 61.92 ± 0.004
- - - - (1.4 ± 0.0001)E9 79.91 ± 0.004
- - - - (4.4 ± 0.0005)E9 79.91 ± 0.004
- - 6.07E7 45.19 - -

Rate Dhib and Al-Nidawy [37] Yao et al. [1] Agrawal et al. [4]
constant
A (1/s) E (kJ/mol) A (1/s) E (kJ/mol) A (1/s) E (kJ/mol)
1.81E16 177.02 2.29E14 126.05 1.00E14 119.85
6.04E13 175.49 - - 1.00E12 123.03
- - - - 1.6E11 132.08
6.04E3 305.20 6.04E3 305.17 - -
5.45E5 17.61 9.90E5 17.61 4.00E5 17.42
4.35E8 15.27 4.35E8 15.27 8.70E8 15.27
- - 3.25E8 1.01 - -
- - - - 7.70E9 79.91
1.20E5 60.25 1.2E5 60.24 - -
1.80E8 39.32 1.8E8 39.33 5.20E4 36.82
- - 5.60E7 41.97 7.00E4 18.39
3.25E5 31.27 - - 1.20E10 60.50
1.40E9 80.75 1.40E9 79.91 1.40E9 84.69
- - 4.40E9 79.91 4.40E9 70.16
- - - - - -

model showed that axial mixing can be neglected for all practical conducted later on by numerous researchers eliminate axial
purposes using the same reactor system of Agrawal and Han [30]. mixing assumption from their model.
Furthermore, Donati et al. [34] and Yoon and Rhee [31] also An overview of information on modelling studies on
remarked that axial mixing contribute insignificant effect on the LDPE reactors available in the open literature indicates
reactor performance and therefore can be neglected under typical significant discrepancies among researchers for kinetic
industrial operating conditions. Therefore, most of the studies constants as summarized in Table 3. Brandolin et al. [13]
attempted to establish reliable kinetic data which utilized the

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initiation by oxygen, propagation, and termination by of precipitated gets attached to reactor inner wall. In the
combination, thermal degradation and chain-transfer reaction following study, Buchelli et al. [43] used computational fluid
mechanism. The authors determined the kinetic rate parameters dynamic (CFD) simulation to investigate the effect of fouling
using a non-linear regression analysis of data obtained from two on reactor temperature, polymer properties and monomer
different reactor configurations with regards to their temperature conversion. However, their prediction of reactor wall inside
profile and molecular properties. The model was able to predict temperature was contradict to observed temperature in the
reactor states and product properties. Following this, Brandolin et real plant. This should act as impetus for the future researcher
al. [18] extended their previous model by incorporating realistic to study the fouling effect since it may lead to runaway
features such as multiple initiator injections and included typical condition in LDPE tubular reactor.
heat-transfer coefficients obtained from plant data. However, they Several studies on the optimization of LDPE are
showed the kinetic rate parameters for initiators and telogen in a available in the literatures. Yoon and Rhee [31] focus on the
range due to maintain confidentiality of their work. Same maximization of monomer conversion as their objective
procedure was repeated by Zabisky et al. [32] as they also did not function. However, the authors did not highlight the polymer
provide the kinetic rate parameters obtained after validation of quality (through MWD) in their study. Mavridis and
model to industrial data due to proprietary reasons. Agrawal et al. Kiparissides [36] derived a general mathematical model that
[4] gave the tuned kinetic rate constant values in their paper. maximized the reactor productivity while maintaining the
Their model were based from Asteasuain et al. [35], which product quality in terms of monomer conversion and the
provide the design features, steady-state operating conditions, moments of MWD. Important conclusion of their work and
measured temperature profile along the reactor length, monomer used in the subsequent study is polymer with specified
conversion and number-average molecular weight at reactor exit. molecular weight characteristics is obtainable through proper
Agrawal et al. [4] have included chain transfer to polymer, β- manipulation of the control variables. Nevertheless, their
scission of secondary radical and tertiary radical reactions to the work was rather too general and some of the reaction kinetics
original kinetic scheme used by Asteasuain et al. [35]. Physical was missing from their model. Kiparissides et al. [44]
properties and pressure variations along the axial length included developed an on-line multi-level optimization based on a
are their new contribution to the Asteasuain steady state model. They include parameter estimation in
et al. [35] model. However, Agrawal et al. [4] neglect some of the their study and considered ethylene conversion and product
reaction mechanism notably monomer thermal initiation, quality as their objective function.
termination by disproportionation and generation of inert. Cervantes et al. [45] used a simplified nonlinear
According to Ray and Laurence [38], molecular weight model to obtain optimal switching time between different
distribution (MWD) of the polymer plays significant role in steady states (correspond to two different polymer grades)
determining the polymer quality. As a consequence, a principal with a feed mixture of ethylene, methane, butane and
theme in all modelling efforts in LDPE manufacturing is directed impurities. Asteasuain et al. [27] attempted a study optimal
towards MWD of the polymer. Hulburt and Katz [39] proposed start-up policies of LDPE reactor. Maximization outlet
the method of moments in their study. Although their primary conversion and the product quality are their objective
focus was on nucleation and growth kinetics commonly function while feed flow rates of initiators and telogens are
encountered in crystal growth studies, they realised that their used as decision variables. However, the authors did not
approach could be easily extended to include other kinds of include shutdown strategies in their optimization study. Yao
"particles". In term of LDPE production that term of “particles” et al. [1] applied genetic algorithm to obtain the optimal
would mean the free-radical polymerization. A method of jacket temperature profile required to maximize the polymer
moments for polymer size distribution in time was studied productivity. Their model include focus on the utilization of
rigorously by Katz and Seidel [40]. They considered basic reactor length, and observed that conversion as high as
reaction of initiation, propagation and termination by combination 42.33% (highest than any reported previously) is obtainable
in their kinetic mechanism. One of the most important discovery through the implementation of 5 initiator injections.
of their research is that monomer conversion and polymer size Nevertheless, their work is not validated with any of the
distribution was controlled by a suitable defined dimensionless experimental or industrial data.
group. The authors also highlighted the effect of inclusion of Agrawal et al. [4] focus on maximization of
chain transfer and termination by disproportionation in reaction monomer conversion and minimization of undesirable side
mechanism. Seidel and Katz [41] continued the study by products using binary coded non-dominated sorting genetic
describing a dynamic analysis of branching in free-radical algorithm and jumping gene adaptations. Their work was
polymerization in terms of the moments of the polymer size based on the dynamic model by Asteasuain et al. [35], with
distributions, the mean number of branches and the rate of various modification and additional of kinetic mechanism
polymerization. An important findings of this study was that taking place. Zavala and Biegler [22] derive a general
chain-transfer reactions have significant effect of widening the nonlinear model predictive control (NMPC) with the
final product MWD. This findings has been used in many integration of moving horizon estimation (MHE) strategies to
subsequent LDPE polymerization modeling studies. optimize the operation of LDPE tubular reactors. Their
Extensive research to determine the fouling inside tracking NMPC controller is able to stabilize the reactor in
tubular reactor was done by Buchelli et al. [42]. They had used the case of persistent fouling disturbances. Erdeghem at al.
the heat transfer model and industrial data to calculate the fouling [46] works are more towards profit oriented. The first study
thickness and fouling deposition rate over time. The authors was more focusing on maximize the LDPE productivity
concluded that fouling in a reactor was caused by a tiny fraction while minimizing the investment cost. Their pareto optimal

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study of multi-peak models was able to identify where along the M Ethylene monomer
tubular reactor and how much amount of initiator has to be O2 Oxygen
injected to maximize the profit at different economic situations. P(m) Polymer molecule of chain length m, (m= 1, ..., )
Their subsequent study was to identify the most optimum reactor P Reactor pressure
configuration. A short cold cooling zone in the first and last peak
R(m) Living radical of chain length m, (m= 0, ..., )
and longer cooling zones in the second and third peak was
observed to be the most optimum reactor. S Fictitious transfer agent
TJ Jacket temperature
X Inert molecule.
CONCLUSION
Although numerous efforts directed towards a realistic model
development and improvement are abundant in the literatures, REFERENCES
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