Computational Fluid Dynamics Simulations Applied to Polymerization Reactor Design: A Case Study of Tubular Loop Reactor

The loop reactor for polyolefin production involves complex interactions between liquid–solid flow and polymerization reaction, which significantly influence the reactor’s overall performance. Computational fluid dynamics (CFD) offers valuable insights into these interactions, thereby aiding in the design of reactor configurations and operating parameters. In this study, a three-dimensional CFD model of a pilot-scale loop reactor is developed by integrating the Euler–Euler model, the kinetic theory of granular flow, and a simplified polymerization kinetics scheme. Specifically, a general procedure for reactor design based on CFD modeling is outlined, in which the uniformity index is used to assess the reactor’s performance. Based on this procedure, key configuration and operating parameters for the loop reactor are selected. The simulation results provide design recommendations for the loop reactor’s bend geometry, guide vanes, axial-flow pump speed, and jacket cooling water temperature. This study offers valuable insights and guidance for the design of general reactors.