Improved Polymer Process Operability and Control through Steady-State and Dynamic Simulation Models

Abstract

This chapter introduces a novel approach to dynamic polymer process modeling using Aspen Plus and Aspen Plus Dynamics (AD). By transitioning from steady-state to dynamic simulation, we present a powerful tool for analyzing and optimizing polymer production processes, offering deeper insights into process operability and control.

We outline a comprehensive workflow for converting steady-state models into dynamic simulations, enabling users to simulate time-dependent behaviors in polymer processes. The chapter explores various aspects of dynamic simulation, including simulation modes, real-time data visualization, and advanced process control strategies. We also integrate key tasks such as PID controller configuration, snapshot management, and discrete event sequencing to enhance the management of complex polymer production scenarios, particularly grade transitions.

Through practical workshops and case studies, we demonstrate the application of these dynamic simulation techniques to industrial polymer processes, focusing on high-density polyethylene (HDPE) and linear low-density polyethylene (LLDPE) production. The methodologies and insights presented aim to equip engineers and researchers with effective tools for implementing dynamic simulations, ultimately improving process efficiency and control in polymer manufacturing.

This is a preprint version of a chapter from our book - Integrated Process Modeling, Advanced Control and Data Analytics for Optimizing Polyolefin Manufacturing [22,31]. Please cite the original work if referenced