Optimal flowsheet configuration of a polymerization process with embedded molecular weight distributions

Abstract

We consider the optimal reactor network synthesis of a polymerization process with detailed molecular weight distributions (MWDs). Based on an industrial high‐density polyethylene (HDPE) slurry process model including an embedded MWD, a fully connected process superstructure of continuous stirred tank reactors (CSTRs) is established through the introduction of splitters. Using this generalized superstructure as a basis, two nonlinear programming (NLP) problem formulations, which simultaneously maximize the monomer conversion and minimize the deviation between the calculated and target MWDs, are developed by applying multiobjective optimization (MO) methods. Different optimal flowsheet configurations are generated by systematically manipulating a set of continuous decision variables. Several case studies that consider different specifications on MWD are conducted to illustrate the effectiveness and efficiency of the proposed synthesis approach. Numerical results show that the optimal flowsheet configurations overcome the limitations of conventional reactor network structures and help to increase reactor productivity at the desired product quality. © 2015 American Institute of Chemical Engineers AIChE J, 62: 131–145, 2016