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Materials 2014, 7(4), 2440-2458;

Polypropylene Production Optimization in Fluidized Bed Catalytic Reactor (FBCR): Statistical Modeling and Pilot Scale Experimental Validation

Department of Chemical Engineering, Faculty of Engineering, University of Malaya, 50603 Kuala Lumpur, Malaysia
UM Power Energy Dedicated Advanced Centre (UMPEDAC), Wisma R & D, University of Malaya, 59990 Kuala Lumpur, Malaysia
Chemical Engineering Division, School of Engineering, University of Bradford, Bradford BD7 1DP, UK
Author to whom correspondence should be addressed.
Received: 13 December 2013 / Revised: 12 March 2014 / Accepted: 13 March 2014 / Published: 27 March 2014
(This article belongs to the Section Manufacturing Processes and Systems)
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Propylene is one type of plastic that is widely used in our everyday life. This study focuses on the identification and justification of the optimum process parameters for polypropylene production in a novel pilot plant based fluidized bed reactor. This first-of-its-kind statistical modeling with experimental validation for the process parameters of polypropylene production was conducted by applying ANNOVA (Analysis of variance) method to Response Surface Methodology (RSM). Three important process variables i.e., reaction temperature, system pressure and hydrogen percentage were considered as the important input factors for the polypropylene production in the analysis performed. In order to examine the effect of process parameters and their interactions, the ANOVA method was utilized among a range of other statistical diagnostic tools such as the correlation between actual and predicted values, the residuals and predicted response, outlier t plot, 3D response surface and contour analysis plots. The statistical analysis showed that the proposed quadratic model had a good fit with the experimental results. At optimum conditions with temperature of 75 °C, system pressure of 25 bar and hydrogen percentage of 2%, the highest polypropylene production obtained is 5.82% per pass. Hence it is concluded that the developed experimental design and proposed model can be successfully employed with over a 95% confidence level for optimum polypropylene production in a fluidized bed catalytic reactor (FBCR). View Full-Text
Keywords: polypropylene; process parameter; optimization; fluidized bed reactor polypropylene; process parameter; optimization; fluidized bed reactor
This is an open access article distributed under the Creative Commons Attribution License (CC BY 3.0).

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Khan, M.J.H.; Hussain, M.A.; Mujtaba, I.M. Polypropylene Production Optimization in Fluidized Bed Catalytic Reactor (FBCR): Statistical Modeling and Pilot Scale Experimental Validation. Materials 2014, 7, 2440-2458.

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