CHP633 Design Project Outline

Physical chemistry and thermodynamics are often very theoretical subjects,

dealing with ideal situations that are difficult or impossible to replicate in reality.
Engineers and technologists utilize the principles of physical chemistry to guide
the design of actual processes and process components, while providing
appropriate “overdesign” to accommodate non-ideal behaviour. A common
application of physical chemistry principles is in the design of pressure vessels to
contain high-pressure reactants. A common example of a pressure vessel is a
compressed gas cylinder, but pressure vessels include any process component
designed to hold pressure.

For this design project, you are to summarize the requirements of a pressurized
reactor intended to contain the high-pressure polymerization reaction of ethylene
into low-density polyethylene (LDPE). A basic diagram of the high-pressure
polymerization process and reaction equation is shown below.

C2H4 + C2H4 + C2H4 … (× n) Peroxide, heat, pressure [C2H4]n

Ethylene recycle
Staged Additive
compressors injection pump
Ethylene
Separation
column

Ethylene Polymerization
storage reactor
tank
Peroxide

Peroxide
injection pump Product cooler LDPE solid

CHP633 Design Project Outline 1

Reactor Details

Pressure rating & type: 1000 bar, cylindrical

Maximum height of 8.50 m

Operating temperature: 260°C

Production capacity: 10.0 te per batch of branched (non-linear) LDPE,

average MW of 46 500 g/mol

Extent of reaction: 92.5% (molar)

Liquid additives: Hindered amine light stabilizers (HALS)

Boric acid as flame retardant

Catalyst: Dibenzoyl peroxide, 30.0 w/v% in water, 0.0033 mol

peroxide per 1.00 mol ethylene

The volume of the liquid additives may be considered small enough to not occupy
any significant volume in the reactor.

Reactor Design

On the provided datasheet, summarize the design parameters listed below for the
reactor. Any calculations or justification used to determine these design
parameters must be summarized on the datasheet (or on additional attached
sheets, if needed).

Material(s) of construction

Choose a specific material (e.g. Teflon, carbon steel, aluminum, etc.) or materials
from which to construct the body of the reactor.

Wall thickness

Determine the wall thickness of the reactor required to withstand the reaction
conditions.

Size

Determine the required internal volume and external dimensions of the reactor.

Submission

The Design Project Datasheet is due at the end of Study Break (Week 8) on
Sunday at 11:59 PM. Submission is on my.Seneca.

CHP633 Design Project Outline 2

CHP633 Design Project Datasheet

Reactor material(s)

Wall thickness (mm)

Internal volume (L)

Dimensions (m) Height Diameter

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Calculations

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