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Rohman F, Othman MR, Muhammad D, Azmi A, Idris I, Ilyas RA, Elkhatif SE, Murat MN. Nonlinear Control of Fouling in Polyethylene Reactors. ACS OMEGA 2022; 7:39648-39661. [PMID: 36385840 PMCID: PMC9648127 DOI: 10.1021/acsomega.2c03078] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/17/2022] [Accepted: 09/13/2022] [Indexed: 06/16/2023]
Abstract
Fouling formation in reactor vessels poses a serious threat to the safe operation of the industrial low-density polyethylene (LDPE) polymerization. Fouling also degrades the polymer quality and causes productivity loss to some extent. In this work, neural Wiener model predictive control (NWMPC) is introduced to address the fouling concern. In addition, a soft sensor model is used to activate the fouling-defouling (F-D) mechanism when the fouling surpasses the thickness limit to prevent vessel overheating. NWMPC is proven to be fast, stable, and robust under various control scenarios. The use of a soft sensor model in conjunction with NWMPC enables the online monitoring and controlling of the F-D processes. When comparison is made with a state space (SSMPC) utilizing only the linear block, NWMPC is found to be able to control the LDPE grade with quicker grade transition and lower resource consumption.
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Affiliation(s)
- Fakhrony
Sholahudin Rohman
- School
of Chemical Engineering, Engineering Campus,
Universiti Sains Malaysia, Nibong Tebal, 14700Penang, Malaysia
| | - Mohd Roslee Othman
- School
of Chemical Engineering, Engineering Campus,
Universiti Sains Malaysia, Nibong Tebal, 14700Penang, Malaysia
| | - Dinie Muhammad
- School
of Chemical Engineering, Engineering Campus,
Universiti Sains Malaysia, Nibong Tebal, 14700Penang, Malaysia
| | - Ashraf Azmi
- School
of Chemical Engineering, College of Engineering, Universiti Teknologi MARA, Shah Alam, 40450Selangor, Malaysia
| | - Iylia Idris
- School
of Chemical Engineering, College of Engineering, Universiti Teknologi MARA, Shah Alam, 40450Selangor, Malaysia
| | - Rushdan Ahmad Ilyas
- School
of Chemical and Energy Engineering, Faculty of Engineering, Universiti Teknologi Malaysia (UTM), Johor Bahru, 81310Johor, Malaysia
- Centre
for Advanced Composite Materials (CACM), Universiti Teknologi Malaysia (UTM), Johor Bahru, 81310Johor, Malaysia
- Institute
of Tropical Forestry and Forest Products, Universiti Putra Malaysia (UPM), Serdang, 43400Selangor, Malaysia
| | - Samah Elsayed Elkhatif
- Mechanical
Engineering, Faculty of Engineering and Technology, Future University in Egypt, New Cairo11845, Egypt
| | - Muhammad Nazri Murat
- School
of Chemical Engineering, Engineering Campus,
Universiti Sains Malaysia, Nibong Tebal, 14700Penang, Malaysia
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2
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Dietrich ML, Sarmoria C, Brandolin A, Asteasuain M. Modeling Low‐Density Polyethylene (LDPE) Production in Tubular Reactors: Connecting Polymerization Conditions with Polymer Microstructure and Rheological Behavior. MACROMOL REACT ENG 2022. [DOI: 10.1002/mren.202200003] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/07/2022]
Affiliation(s)
- Maira L. Dietrich
- Planta Piloto de Ingeniería Química (PLAPIQUI) Universidad Nacional del Sur‐CONICET Camino La Carrindanga km 7 Bahía Blanca 8000 Argentina
| | - Claudia Sarmoria
- Planta Piloto de Ingeniería Química (PLAPIQUI) Universidad Nacional del Sur‐CONICET Camino La Carrindanga km 7 Bahía Blanca 8000 Argentina
- Departamento de Ingeniería Química Universidad Nacional del Sur (UNS) Avenida Alem 1253 Bahía Blanca 8000 Argentina
| | - Adriana Brandolin
- Planta Piloto de Ingeniería Química (PLAPIQUI) Universidad Nacional del Sur‐CONICET Camino La Carrindanga km 7 Bahía Blanca 8000 Argentina
- Departamento de Ingeniería Química Universidad Nacional del Sur (UNS) Avenida Alem 1253 Bahía Blanca 8000 Argentina
| | - Mariano Asteasuain
- Planta Piloto de Ingeniería Química (PLAPIQUI) Universidad Nacional del Sur‐CONICET Camino La Carrindanga km 7 Bahía Blanca 8000 Argentina
- Departamento de Ingeniería Química Universidad Nacional del Sur (UNS) Avenida Alem 1253 Bahía Blanca 8000 Argentina
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3
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Molecular weight distribution modeling of LDPE in a continuous stirred-tank reactor using coupled deterministic and stochastic approach. KOREAN J CHEM ENG 2022. [DOI: 10.1007/s11814-021-0943-9] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
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Zentel KM, Busch M. Predicting Polymer Properties via a Coupled Kinetic, Stochastic and Rheological Modeling Approach from Reaction Conditions. MACROMOL REACT ENG 2021. [DOI: 10.1002/mren.202100027] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Kristina M. Zentel
- Institute for Technical and Macromolecular Chemistry Technical University of Darmstadt Alarich‐Weiß‐Straße 8 64287 Darmstadt Germany
| | - Markus Busch
- Institute for Technical and Macromolecular Chemistry Technical University of Darmstadt Alarich‐Weiß‐Straße 8 64287 Darmstadt Germany
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5
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Initiator Feeding Policies in Semi-Batch Free Radical Polymerization: A Monte Carlo Study. Processes (Basel) 2020. [DOI: 10.3390/pr8101291] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
A Monte Carlo simulation algorithm is developed to visualize the impact of various initiator feeding policies on the kinetics of free radical polymerization. Three cases are studied: (1) general free radical polymerization using typical rate constants; (2) diffusion-controlled styrene free radical polymerization in a relatively small amount of solvent; and (3) methyl methacrylate free radical polymerization in solution. The number- and weight-average chain lengths, molecular weight distribution (MWD), and polymerization time were computed for each initiator feeding policy. The results show that a higher number of initiator shots throughout polymerization at a fixed amount of initiator significantly increases average molecular weight and broadens MWD. Similar results are also observed when most of the initiator is added at higher conversions. It is demonstrated that one can double the molecular weight of polystyrene and increase its dispersity by 50% through a four-shot instead of a single shot feeding policy. Similar behavior occurs in the case of methyl methacrylate, while the total time drops by about 5%. In addition, policies injecting initiator at high monomer conversions result in a higher unreacted initiator content in the final product. Lastly, simulation conversion-time profiles are in agreement with benchmark literature information for methyl methacrylate, which essentially validates the highly effective and flexible Monte Carlo algorithm developed in this work.
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Taheri AR, Najafi M, Motahari S. A New Monte Carlo Simulation of Low-Density-Polyethylene Polymerization for Prediction of its Microstructure as a Result of Various Process Conditions. J MACROMOL SCI B 2020. [DOI: 10.1080/00222348.2020.1743013] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
Affiliation(s)
- Ahmad R. Taheri
- Department of Polymer Engineering, School of Chemical Engineering, College of Engineering, University of Tehran, Tehran, Iran
| | - Mohammad Najafi
- Department of Polymer Engineering, School of Chemical Engineering, College of Engineering, University of Tehran, Tehran, Iran
| | - Siamak Motahari
- Department of Polymer Engineering, School of Chemical Engineering, College of Engineering, University of Tehran, Tehran, Iran
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7
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Cremer‐Bujara E, Biessey P, Grünewald M. Simulation of Polymer Reactors Using the Compartment Modeling Approach. MACROMOL REACT ENG 2019. [DOI: 10.1002/mren.201900034] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Affiliation(s)
| | - Philip Biessey
- Ruhr University Bochum Universitätsstr. 150 44801 Bochum Germany
| | - Marcus Grünewald
- Ruhr University Bochum Universitätsstr. 150 44801 Bochum Germany
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8
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Pladis P, Kiparissides C. 110th Anniversary: Nonideal Mixing Phenomena in High-Pressure Low-Density Polyethylene Autoclaves: Prediction of Variable Initiator Efficiency and Ethylene Decomposition. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b02517] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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9
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Dietrich ML, Sarmoria C, Brandolin A, Asteasuain M. LDPE Production in Tubular Reactors: Comprehensive Model for the Prediction of the Joint Molecular Weight-Short (Long) Chain Branching Distributions. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.8b05713] [Citation(s) in RCA: 8] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Maira L. Dietrich
- Planta Piloto de Ingeniería Química (PLAPIQUI), Universidad Nacional del Sur-CONICET, Camino La Carrindanga km 7, Bahía Blanca 8000, Argentina
| | - Claudia Sarmoria
- Planta Piloto de Ingeniería Química (PLAPIQUI), Universidad Nacional del Sur-CONICET, Camino La Carrindanga km 7, Bahía Blanca 8000, Argentina
- Departamento de Ingeniería Química, Universidad Nacional del Sur (UNS), Avenida Alem 1253, Bahía Blanca 8000, Argentina
| | - Adriana Brandolin
- Planta Piloto de Ingeniería Química (PLAPIQUI), Universidad Nacional del Sur-CONICET, Camino La Carrindanga km 7, Bahía Blanca 8000, Argentina
- Departamento de Ingeniería Química, Universidad Nacional del Sur (UNS), Avenida Alem 1253, Bahía Blanca 8000, Argentina
| | - Mariano Asteasuain
- Planta Piloto de Ingeniería Química (PLAPIQUI), Universidad Nacional del Sur-CONICET, Camino La Carrindanga km 7, Bahía Blanca 8000, Argentina
- Departamento de Ingeniería Química, Universidad Nacional del Sur (UNS), Avenida Alem 1253, Bahía Blanca 8000, Argentina
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Yaghini N, Iedema PD. New models of radical polymerization with branching and scission predicting molecular weight distribution in tubular and series of continuous stirred tank reactors allowing for multiradicals and gelation. Chem Eng Sci 2015. [DOI: 10.1016/j.ces.2015.02.044] [Citation(s) in RCA: 6] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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11
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Pladis P, Meimaroglou D, Kiparissides C. Prediction of the Viscoelastic Behavior of Low-Density Polyethylene Produced in High-Pressure Tubular Reactors. MACROMOL REACT ENG 2015. [DOI: 10.1002/mren.201500008] [Citation(s) in RCA: 14] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
Affiliation(s)
- Prokopios Pladis
- Chemical Process & Energy Resources Institute; Centre for Research and Technology Hellas; Thessaloniki Greece
| | - Dimitrios Meimaroglou
- CNRS; LRGP; UMR 7274 Nancy F-54001 France
- Université de Lorraine; LRGP; UMR 7274 Nancy F-54001 France
| | - Costas Kiparissides
- Chemical Process & Energy Resources Institute; Centre for Research and Technology Hellas; Thessaloniki Greece
- Department of Chemical Engineering; Aristotle University of Thessaloniki; P.O. Box 472 Thessaloniki 54124 Greece
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12
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Zhu YP, Luo ZH, Xiao J. Multi-scale product property model of polypropylene produced in a FBR: From chemical process engineering to product engineering. Comput Chem Eng 2014. [DOI: 10.1016/j.compchemeng.2014.07.013] [Citation(s) in RCA: 9] [Impact Index Per Article: 0.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/25/2022]
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13
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Yaghini N, Iedema PD. Molecular Weight and Branching Distribution Modeling in Radical Polymerization with Transfer to Polymer and Scission Under Gel Conditions and Allowing for Multiradicals. Macromolecules 2014. [DOI: 10.1021/ma501094a] [Citation(s) in RCA: 14] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
| | - Piet D. Iedema
- Van’t
Hoff Institute
for Molecular Sciences, University of Amsterdam, Science Park 904, 1098 XH Amsterdam, The Netherlands
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14
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Abstract
Population balance modeling is undergoing phenomenal growth in its applications, and this growth is accompanied by multifarious reviews. This review aims to fortify the model's fundamental base, as well as point to a variety of new applications, including modeling of crystal morphology, cell growth and differentiation, gene regulatory processes, and transfer of drug resistance. This is accomplished by presenting the many faces of population balance equations that arise in the foregoing applications.
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Affiliation(s)
| | - Meenesh R. Singh
- School of Chemical Engineering, Purdue University, West Lafayette, Indiana 47907
- Department of Chemical and Biomolecular Engineering, University of California, Berkeley, California 94704
- Joint Center for Artificial Photosynthesis, Lawrence Berkeley National Laboratory, Berkeley, California 94720
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15
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Van Steenberge P, D’hooge D, Reyniers MF, Marin G. Improved kinetic Monte Carlo simulation of chemical composition-chain length distributions in polymerization processes. Chem Eng Sci 2014. [DOI: 10.1016/j.ces.2014.01.019] [Citation(s) in RCA: 90] [Impact Index Per Article: 9.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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16
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Meimaroglou D, Kiparissides C. Review of Monte Carlo Methods for the Prediction of Distributed Molecular and Morphological Polymer Properties. Ind Eng Chem Res 2014. [DOI: 10.1021/ie4033044] [Citation(s) in RCA: 43] [Impact Index Per Article: 4.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Dimitrios Meimaroglou
- CNRS,
LRGP, UMR 7274, Nancy, F-54001, France
- Université de Lorraine, LRGP, UMR 7274, Nancy, F-54001, France
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17
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Bain ED, Turgman-Cohen S, Genzer J. Progress in Computer Simulation of Bulk, Confined, and Surface-initiated Polymerizations. MACROMOL THEOR SIMUL 2012. [DOI: 10.1002/mats.201200030] [Citation(s) in RCA: 22] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/13/2022]
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18
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Becker PJ, Puel F, Henry R, Sheibat-Othman N. Investigation of Discrete Population Balance Models and Breakage Kernels for Dilute Emulsification Systems. Ind Eng Chem Res 2011. [DOI: 10.1021/ie2006033] [Citation(s) in RCA: 35] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Per Julian Becker
- Université de Lyon, Université Lyon 1, CNRS, CPE Lyon, UMR 5007, Laboratoire d’Automatique et de Génie des Procédés (LAGEP), 43 Bd du 11 Novembre 1918, F-69622 Villeurbanne, France
| | - François Puel
- Université de Lyon, Université Lyon 1, CNRS, CPE Lyon, UMR 5007, Laboratoire d’Automatique et de Génie des Procédés (LAGEP), 43 Bd du 11 Novembre 1918, F-69622 Villeurbanne, France
| | - Reynald Henry
- Université de Lyon, Université Lyon 1, CNRS, CPE Lyon, UMR 5007, Laboratoire d’Automatique et de Génie des Procédés (LAGEP), 43 Bd du 11 Novembre 1918, F-69622 Villeurbanne, France
| | - Nida Sheibat-Othman
- Université de Lyon, Université Lyon 1, CNRS, CPE Lyon, UMR 5007, Laboratoire d’Automatique et de Génie des Procédés (LAGEP), 43 Bd du 11 Novembre 1918, F-69622 Villeurbanne, France
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