Process Modeling for Propylene Polymerization to Transfer Reaction Kinetics From Lab to Plant

In this work, a methodology is presented to develop an industrial process model for polypropylene production using a newly developed Ziegler–Natta catalyst. The approach couples an industrial process model with kinetics obtained from lab-scale polymerization experiments. First, the process model is developed and validated for an industrially well-known fourth-generation catalyst. Then, kinetic parameters for a novel fifth-generation catalyst are derived from lab data and included in the industrial model. Production rates can be predicted accurately using this approach, whereas deviations in melt flow rate require additional adjustment. The study demonstrates that lab-derived kinetics can support industrial catalyst model implementation. Nevertheless, validation should always be performed using available plant data.