A model is developed for hydrolytic copolymerization of caprolactam with hexamethylene diamine (HMD) and adipic acid (ADA) in a batch reactor to produce nylon 6/6,6 copolymer. The reaction mechanism includes hydrolysis of caprolactam and cyclic dimer, polycondensation, polyaddition, transamidation, and ring formation via end biting and back biting. The catalyzing effect of carboxyl groups is accounted for using kinetic parameters from the literature. Model predictions are compared with low‐temperature literature data before simulating reactor conditions of industrial interest. The model predicts a higher degree of polymerization (DP) for nylon 6/6,6 copolymer compared to nylon 6 and 6,6 homopolymers produced using the same reactor conditions. Dynamic changes in concentrations of water, caprolactam, HMD, ADA, and end groups are tracked and used to explain the positive influence of comonomers on reaction rates and DP. Insights gained from this model will form a useful basis to build future models of continuous industrial reactors.

A model is used to simulate batch copolymerization of caprolactam with hexamethylene diamine (HMD) and adipic acid (ADA) to produce nylon 6/6,6. Four different recipes are considered: a recipe containing caprolactam and an aqueous solution of HMD and ADA, a recipe containing caprolactam and dry HMD/ADA salt, and two recipes with a portion of the caprolactam replaced by nylon 6 cyclic dimer (CD). Consuming CD would be advantageous because CD is an undesirable side product from nylon 6 production. Simulation results lead to three important findings: (i) operation using dry salt rather than aqueous salt solution leads to higher degree of polymerization, (ii) substantial quantities of CD can be consumed to produce nylon 6/6,6 copolymer, and (iii) including water in the recipe is beneficial for achieving improved consumption of CD. The results of this study will be helpful in designing experiments aimed at improving industrial nylon 6/6,6 copolymerization processes.

Nylon 6 and nylon 6,6 reaction equilibria depend in a complex way on water concentration and temperature. For example, data sets from six research groups reveal that the apparent equilibrium constant for polycondensation increases with water at low water concentrations, reaches a maximum, and then decreases as the water concentration rises further. In this article, semi‐empirical expressions are proposed to describe the experimentally observed equilibrium behavior for the five main reactions that occur during nylon 6 and nylon 6,6 polymerization. Nine side reactions involving amidine ends, cyclopentanone ends, and hydrated carboxyl ends are used to develop expressions that account for the influence of both water and temperature on these equilibrium constants. Excellent fit to the data, over the entire range of the available nylon 6 and nylon 6,6 literature data, suggests that the proposed equations will be helpful for modeling reaction equilibria for nylon 6/6,6 copolymerization.

To understand why some parameters are difficult to estimate in polymerization models, a new diagnostic methodology is proposed. This method is then used to investigate whether parameter estimability difficulties arise from the small influence of certain parameters on model predictions or from correlated effects with other parameters. The proposed method builds on a popular orthogonalization‐based parameter‐ranking algorithm that ranks parameters from the most estimable to the least estimable. A nylon 6/6,6 copolymerization model and a bio‐based polyether (PO3G) model are used to illustrate the effectiveness of the proposed methodology. Diagnosis of the nylon 6/6,6 model reveals that correlated behavior among six parameters related to nylon 6 cyclic dimer formation leads to parameter‐estimation difficulties. Diagnosis of the PO3G model reveals that difficulties in estimating low‐ranked parameters are mainly due to low‐sensitivities of some parameters and to lack of information about these parameters in the data. The proposed methodology will help future modelers make decisions about simplification of their model equations and about possible future experiments aimed at obtaining reliable parameter estimates and model predictions.

Nylon 6 and 6,6 literature data are collected over a wide range of water concentrations and temperatures (0 ≤ [W]0 ≤ 40.8 wt%, 200 ≤ T ≤300 °C) and used to fit parameters in an updated batch reactor model. The resulting copolymerization model uses side reactions to account for the complex influence of water on kinetics and reaction equilibria. The proposed parameter estimates result in a significant improvement in the fit to the data, corresponding to a 73% reduction in the weighted‐least‐squares objective function compared to when the parameters of Arai et al. are used. Copolymerization simulations are conducted at industrially relevant conditions, shedding light on the complex influence of water and on the potential to include waste nylon 6 cyclic dimer in the feedstock. The model and parameter estimates will be helpful in future models of nylon 6/6,6 copolymerization in continuous reactor systems.