Modeling and Simulation of a Multizone Circulating Reactor for Polyethylene Production with Internal Cooling

Polyolefins play a role in industries and are typically manufactured using two types of reactors: high-pressure tubular reactors and fluidized bed reactors. An innovative technology called the Multizone Circulating reactor (MZCR) has emerged, which introduces an innovative approach with interconnected polymerization zones creating a continuous loop of polymer flow. This study focuses on modeling and simulating ethylene gas phase polymerization within the MZCR in the presence of internal cooling to gain insights into its behavior. To achieve this, a comprehensive computational fluid dynamics (CFD) simulation was developed. It considered momentum, material, and energy balance aspects. The model equations were solved using the finite difference method in COMSOL Multiphysics version 6.1. The investigation primarily focused on studying the impact of incorporating a cooler into the riser section on the temperature profile within the reactor and ethylene conversion. The presence of this cooler resulted in a reduction in temperature change along the riser from approximately 8.0 °C to 4.0 °C. Moreover, it led to an increase of 7%, in ethylene single-pass conversion.