Mixing effects on performance and stability of low‐density polyethylene reactors

Imperfect initiator mixing greatly affects the stability and efficiency of low density polyethylene (LDPE) autoclave reactors. A combined simulation technique utilizing compartment models and computational fluid dynamics extends previous work in the literature by providing a physically detailed picture of imperfect mixing. Analysis indicates that the effective volume for chain propagation in the autoclave reactor can expand and contract in a continuous fashion as operating conditions change. As mixing becomes poor, the effective reactive volume decreases, causing a reduction in initiator efficiency, but an expansion in the stable operation region. Examples demonstrate that accurate prediction of the effective reaction volume is crucial for predicting LDPE autoclave reactor behavior. A new mixing model that represents the feed plume by a series of interconnected tanks with geometrically increasing volumes provides a favorable tradeoff between accuracy and model complexity. © 2005 American Institute of Chemical Engineers AIChE J, 2005