Control of semicontinuous emulsion copolymerization reactors

Saldívar, Enrique; Ray, W. Harmon

doi:10.1002/aic.690430811

Cited by 42 publications

(30 citation statements)

References 40 publications

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“…It is well known (c.f. Canegallo et al (1993), Saldívar and Ray (1997)) that, using the integrated form of the Mayo -Lewis equation, composition in terms of conversion can be predicted for most copolymerization systems. In consequence, if one has access to data on conversion evolution with time, the composition can also be predicted as a function of time.…”

Section: General Methodology For Modeling and Scaling-upmentioning

confidence: 99%

A Practical, Systematic Approach for the Scaling‐Up and Modeling of Industrial Copolymerization Reactors

Guerrero‐Sánchez

Saldívar²,

Hernández

et al. 2003

Polymer Reaction Engineering

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A systematic methodology for the modeling and engineering analysis of industrial copolymerization reactors is presented. The methodology, especially suited for the scaling-up from laboratory experiments to pilot plant and industrial reactor level, consists of gradually building models of more complexity in a modular way as more information is obtained from experimental data and/or theoretical considerations. In the first stage, simple models for copolymer composition are written based on the Mayo -Lewis copolymerization equation and empirical copolymerization rate data for different reactor configurations (batch and CSTR) and reactor operations (steady state and some dynamic transients for the CSTR case). This set of models, which use minimal or no data fitting, is shown to be highly predictive. In a second stage, as kinetic information is obtained in the form of an expression for the copolymerization rate, either empirical or mechanistic, the models can be gradually expanded to include a full non-linear analysis of steady state multiplicities and other interesting phenomena, which can have an impact on the practical operation of the reactor. Also, as a complementary tool for the modeling of copolymerization reactors, a new model for the gel effect in polymerization, based on analogies with the familiar diffusion controlled reactions in heterogeneous catalytic reactors, is outlined and used. The methodology is illustrated with examples drawn from industrial reactors in bulk and emulsion, including some industrial reactor data.

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Section: General Methodology For Modeling and Scaling-upmentioning

confidence: 99%

A Practical, Systematic Approach for the Scaling‐Up and Modeling of Industrial Copolymerization Reactors

Guerrero‐Sánchez

Saldívar²,

Hernández

et al. 2003

Polymer Reaction Engineering

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“…1,2 Nevertheless, the current scenario of strong competition and margin reductions is pushing polymer producers to use more efficient reactors, because the long process times and the time spent in cleaning, filling, heating, cooling, and discharging the reactor strongly reduce the production of the semicontinuous reactors. A way to achieve this goal is to replace semicontinuous reactors by continuous systems.…”

Section: Introductionmentioning

confidence: 98%

Scheduling the Production of a Portfolio of Emulsion Polymers in a Single CSTR

Alarcia

Cal

Asúa

2006

Ind. Eng. Chem. Res.

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The production of a portfolio of waterborne adhesives in a single continuous stirred tank reactor (CSTR) was investigated seeking the sequence and the conditions in which the transition product formed in each grade transition had a minimum effect on the adhesive properties of each grade. This information could be gathered by performing a series of grade transitions in the CSTR. However, this approach would be time-consuming and would have a factorial increase with the number of polymer grades. Therefore, in this work, polymer blends were used to evaluate how the adhesive performance of each polymer was affected by the presence of a different polymer grade. On the basis of that information, a production schedule was proposed with the aim of maintaining an in-specification production. The production schedule was then evaluated by means of grade transitions performed in a CSTR. It was found that, by using short residence times and by following the right production schedule, it was possible to maintain the quality of each polymer grade.

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“…Examples of varying sophistication are seen in the works of Chiang et al 50) , Guyot et al 51) , Kravaris et al 52) , Dimitratos et al. 53,54) , Gagnon and MacGregor 55) , Kozub and MacGregor 48 , Vega 56) , Leiza et al 57) , and Saldivar and Ray 49) .…”

Section: Copolymer Composition Controlmentioning

confidence: 94%

“…Tsoukas et al 45) , Congalidis et al 46) , and Choi and Butala 47) have proposed multivariable control models for general free radical copolymerizations. Kozub and MacGregor 48) have proposed a theoretical multivariable case for emulsion polymerization, as have Saldivar and Ray 49) who also included experimental studies.…”

Section: Copolymer Composition Controlmentioning

confidence: 97%

Modeling and semi-batch control of cross-link density distribution in the free-radical copolymerization of vinyl/divinyl monomers

Enright

Zhu²

2000

Macromol. Theory Simul.

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A general model has been developed to describe the cross‐link density development during the free radical copolymerization of vinyl/divinyl monomers. The conventional copolymerization theory based on the terminal model is applied to the cross‐linking system in a novel way. The cross‐link density profile is illustrated for both batch and standard semi‐batch processes. A new semi‐batch feed procedure is proposed that results in a uniform cross‐link density throughout the reaction.

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Control of semicontinuous emulsion copolymerization reactors

Cited by 42 publications

References 40 publications

A Practical, Systematic Approach for the Scaling‐Up and Modeling of Industrial Copolymerization Reactors

A Practical, Systematic Approach for the Scaling‐Up and Modeling of Industrial Copolymerization Reactors

Scheduling the Production of a Portfolio of Emulsion Polymers in a Single CSTR

Modeling and semi-batch control of cross-link density distribution in the free-radical copolymerization of vinyl/divinyl monomers

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