Thesis (Ph.D.) - Cairo University - Faculty of Engineering - Department of Chemical Engineering

This work presents a two-phase model representing propylene Z-N catalytic polymerization for Unipol® technology utilizing Aspen Plus® and the sequential modular simulation approach. This validated model could reach the operating scheme that improves the plant performance.The suggested scheme could accomplish remarkable savings in energy consumption in the process while enhancing the plant throughput. However, due to neglecting the time factor, applying this scheme in reality may lead to hazardous consequences and waste production. Upon, the dynamic model was developed and validated using different operational scenarios.Then, the model utilized to identify process constraints that obstruct the performance improvement. An automated HAZOP study was applied. This quantitative study illustrated that revamping the existing FBR cooling system is essential for applying the suggested scheme.The extra cost for revamping the cycle gas cooler is trivial compared to the potential increase in the process safety and efficiency besides the plant profitability

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