Optimization of High-Density Polyethylene (HDPE) Production Via Ziegler-Natta-Catalyzed Slurry-Phase Polymerization Process for the Philippine Chemical Industry

Slurry phase polymerization is a well-established process in polymer technology that has been used for decades to produce a wide range of polymers, including polyethylene and polypropylene. It involves the polymerization of monomers in a liquid medium, usually a solvent or a mixture of solvents, to form a suspension of polymer particles. However, this process has not been explored and implemented by polyethylene manufacturers in the Philippines. Moreover, recent studies using slurry-phase polymerization models have exhibited low monomer conversion. Hence, this work performed a series of optimization studies to examine the effects and determine the optimum reactor and feed conditions. Reactor configuration was also optimized using sensitivity analysis with consistent polymer attributes. Using Perturbed-Chain Statistical Associating Fluid Theory (PC-SAFT) and Ziegler-Natta polymerization models, the incorporation of optimization and balance blocks led to convergent results and was proven to increase monomer conversion. The optimized model developed in this study has the potential to increase HDPE production in the country.