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Rezultaty
A generic mechanistic module for a Ziegler-Natta catalytic olefin gas-phase copolymerization in a single-phase fluidised bed reactor was developed for a model-based study of the optimal operation of the polymerization reactor unit under either a transient or a steady-state operating mode. Although the dynamic optimisation of such a process during a transition from the production of one polymer grade to a new one highly attracts the industrial interest, the steady state optimisation of the process as long as it produces a polymer grade has tremendous importance for the process economics. Therefore, four optimal operating points corresponding to the four polymer grades were found under steady state maximization of monomer conversion with respect to all the available model inputs.
Three different optimisation problems were investigated in relation to copolymerization FBR model and the above operating points. At the first problem, the optimal grade transition between two polymer grades under a pre-specified reactor control structure was studied. Different optimisation policies, in terms of the group of the decision variables, were tested to minimize a certain objective function mathematically representing the grade transition time and the off-spec production.
The same problem was revisited under the same objective function and constraints using advanced mathematical framework for an integrated approach to the optimal grade transition problem between the same two polymer grades and the simultaneous control structure selection in the polymerization FBR. A Mixed Integer Dynamic Optimisation (MIDO) algorithm was used to address this problem. This algorithm resulted in an optimal control structure and optimal trajectories of the control variables.
The third optimisation case study deals with the transient dynamic operation of the olefin polymerization FBR in a transition campaign-operating envelope studied as a production-scheduling problem. This problem was fully investigated for the case of four polymer grades as a Mixed Integer Dynamic Optimisation (MIDO) problem accounting both for the optimal operating profiles during the changeovers from one grade to another and for the optimal sequence that these transitions should be carried out. The minimisation of the amount of the produced off-spec product and the campaign duration was the driving force for this optimisation problem.
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