Loop slurry periodogram control to prevent reactor fouling and reactor shutdowns

Abstract

Methods for operating a polymerization reactor system are described, and these methods include the steps of contacting a transition metal-based catalyst system with an olefin monomer and an optional olefin comonomer in the polymerization reactor system comprising a loop slurry reactor and a reactor circulating pump under polymerization conditions to produce an olefin polymer; measuring a kW power consumption of the reactor circulating pump to generate power consumption versus time data; converting the power consumption versus time data using frequency analysis to generate intensity versus frequency data at a first frequency interval encompassing a time equal to one-half an average recirculation period in the loop slurry reactor, and intensity versus frequency data at a second frequency interval encompassing a time equal to the average full recirculation period in the loop slurry reactor; and reducing a production rate of the olefin polymer in the loop slurry reactor when a total of a first peak intensity at the first frequency interval and a second peak intensity at the second frequency interval is equal to 10,000 or more, or when the rate of change of the first peak intensity or the rate of change of the second peak intensity is equal to 5,000/hr or more.