Integration of CFD and condensation polymerization chemistry for a commercial multi-jet tubular reactor

This paper discusses a reactor model for simulating single-phase turbulent reacting flows in a commercial multi-jet tubular condensation polymerization reactor. The model integrates momentum, mass and energy balance equations using commercial computational fluid dynamics (CFD) software with a built-in finite-rate/eddy-dissipation formulation to describe turbulence–chemistry interactions. The turbulence fields are obtained using the standard k–ε model. Sensitivity analysis is used to identify the key reactions of importance in the poorly micromixed region. Results include visualization of velocity, pressure, concentration (with and without chemical reactions), and temperature distributions in the reactor. The propensity to form high polymer mass and foul near the reactor inlet is studied for a range of operating conditions. In contrast to the non-reacting CFD conclusion that lower operating rates improve mixing efficiency, the present analysis illustrates how fouling problems can limit operation at lower rates. This analysis may also be used to design reactor internals that maximize performance and operating flexibility.