Optimization of grade transitions in polyethylene solution polymerization processes

This study considers the development of optimization models for grade transition of polyethylene solution polymerization processes. A detailed mathematical model is developed to capture the dynamics of the solution polymerization process. This includes time delay models for vapor and liquid recycle streams as well as a reduced, yet accurate, vapor‐liquid equilibrium (VLE) model derived from rigorous VLE calculations. Simultaneous dynamic optimization approach is applied to solve the optimization problem to reduce off‐spec production time and transition time. Two optimization formulations, single stage and multistage, are developed to deal with single‐value target and specification bands of product properties, respectively. The results show significant reductions in grade transition time and off‐spec production time. In addition, the multistage formulation designed for problems with specification bands outperforms its single stage counterpart. It minimizes transition time and off‐spec production directly, and leads to higher performance control profiles. © 2015 American Institute of Chemical Engineers AIChE J, 62: 1126–1142, 2016