Loop Slurry Reactor Pump Periodogram Control for Fouling Warning
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Solution Overview
Problem
Large-scale commercial polymerization reactors experience periodic and non-random variations leading to reactor fouling and shutdowns, which are difficult to predict and manage effectively using traditional visual monitoring and bandwidth alarms.
Innovation Solution
Implement frequency analysis of reactor circulating pump power consumption data to identify peak intensities and rates of change at specific frequency intervals, triggering corrective actions such as reducing production rates when certain intensity thresholds or rate of change thresholds are met.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional visual monitoring and bandwidth alarms are used to monitor reactor stability, then the monitoring system is simple and easy to operate, but it fails to detect periodic variations that lead to reactor fouling and shutdowns
Solution Approach 1:
The patent replaces traditional visual monitoring and bandwidth alarm systems with frequency analysis of pump power consumption data. This substitution transforms the monitoring approach from qualitative visual assessment to quantitative spectral analysis, enabling detection of periodic variations that precede reactor fouling events without requiring complex additional hardware
Solution Approach 2:
The patent uses pump power consumption as an intermediary parameter to indirectly detect reactor instability. Instead of directly monitoring reactor conditions, the system analyzes variations in pump power consumption that correlate with periodic slurry behavior, providing early warning of fouling events before they occur
2Reliability
If frequency analysis is implemented to detect periodic variations in pump power consumption, then reactor fouling can be predicted with advanced warning, but the analysis and control system becomes more complex
Solution Approach 1:
The system uses existing pump power consumption data, which is already being collected for operational monitoring, and applies frequency analysis to extract predictive information. This self-service approach leverages available data without requiring additional sensors or measurement equipment, reducing the complexity increase that would otherwise result from implementing fouling detection
3Reliability
If the production rate is reduced to prevent reactor fouling, then reactor shutdowns are avoided and continuous operation is maintained, but productivity decreases
Solution Approach 1:
The system performs preliminary detection of periodic variations in pump power consumption that indicate developing fouling conditions. By identifying these variations before they lead to actual fouling events, the system enables proactive adjustment of operating conditions to maintain continuous operation without unnecessary production reductions
Solution Approach 2:
The system continuously monitors pump power consumption and provides feedback on reactor stability conditions. This feedback loop allows for dynamic adjustment of production rates based on real-time detection of periodic variations, optimizing the balance between maintaining continuous operation and preserving productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Provides reliable, advanced warning of reactor instability, reducing the likelihood of fouling and shutdowns by enabling timely corrective measures.
Implementation Method 1
converting the power consumption versus time data using frequency analysis to generate (a) intensity versus frequency data at a first frequency interval encompassing a time equal to one-half an average recirculation period in the loop slurry reactor, and (b) intensity versus frequency data at a second frequency interval encompassing a time equal to the average full recirculation period in the loop slurry reactor
Data Source
AI summary
Methods for operating a polymerization reactor system are described, and these methods include the steps of contacting a transition metal-based catalyst system with an olefin monomer and an optional olefin comonomer in the polymerization reactor system comprising a loop slurry reactor and a reactor circulating pump under polymerization conditions to produce an olefin polymer; measuring a kW power consumption of the reactor circulating pump to generate power consumption versus time data; converting the power consumption versus time data using frequency analysis to generate intensity versus frequency data at a first frequency interval encompassing a time equal to one-half an average recirculation period in the loop slurry reactor, and intensity versus frequency data at a second frequency interval encompassing a time equal to the average full recirculation period in the loop slurry reactor; and reducing a production rate of the olefin polymer in the loop slurry reactor when a total of a first peak intensity at the first frequency interval and a second peak intensity at the second frequency interval is equal to 10,000 or more, or when the rate of change of the first peak intensity or the rate of change of the second peak intensity is equal to 5,000/hr or more.