Modelling, simulation and control of an industrial, semi-batch, emulsion-polymerization reactor

Hvala, Nadja; Aller, Fernando; Miteva, Teodora; Kukanja, Dolores

doi:10.1016/j.compchemeng.2011.05.016

Cited by 35 publications

(23 citation statements)

References 23 publications

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“…Figure ) exploits process variations (seasonal, educts quality, fouling, etc.) and forces operation close to the ‘real’ process constraints by coordinating control moves of manipulated variables (feed profiles and jacket inlet temperature and flowrate) resulting in batch time reduction …”

Section: Some Examples From the Presentmentioning

confidence: 99%

“…and forces operation close to the 'real' process constraints by coordinating control moves of manipulated variables (feed profiles and jacket inlet temperature and flowrate) resulting in batch time reduction. [1,2] This strategy was recently applied to a polymerization process in order to meet the following two objectives: improve temperature control and reduce batch time. Reaction temperature control is an implicit product quality measure.…”

Section: Getting the Most Out Of Polymerization Processes: Online Optmentioning

confidence: 99%

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Models in the Polymer Industry: What Present? What Future?

Vale

Daiss

Naeem

et al. 2013

Macromolecular Symposia

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Summary An industrial perspective on the present and future role of kinetic and process models in the polymer industry is presented. A number of selected examples illustrate the current value of model‐based approaches in supporting and accelerating tasks like process optimization, product development and design of polymerization reactors. In addition, future trends for the application of models in the polymer industry are discussed and areas where further improvement is thought to be needed are carefully underlined.

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Section: Some Examples From the Presentmentioning

confidence: 99%

Section: Getting the Most Out Of Polymerization Processes: Online Optmentioning

confidence: 99%

Models in the Polymer Industry: What Present? What Future?

Vale

Daiss

Naeem

et al. 2013

Macromolecular Symposia

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show abstract

“…The industrial‐scale related papers are mostly discussing on the on‐line monitoring for controlled polymerization. Unfortunately, many of the important reactor variables that are related to the end‐use polymer's properties (e.g., the conversion, MWD etc), cannot be measured through on‐line monitoring . This is due to several factors such as lack of robustness on the on‐line sensors and due to thermodynamically unstable nature of latex particles .…”

Section: Introductionmentioning

confidence: 99%

Batch‐to‐Batch Reproducibility Studies of Pilot‐Scale Emulsion Polymerization of Poly(styrene‐co‐butyl acrylate)

Harmain¹,

Chan

2018

Macromolecular Symposia

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Studies on emulsion polymerization (EP) of poly(styrene‐co‐butyl acrylate) [P(S‐co‐BA)] can be accessed in open literature. However, these studies are mostly focusing on lab‐scale polymerization and subsequently characterization, of which discussion on pilot‐scale or mass‐production‐scale of the polymerization is scant. This paper focuses on the batch‐to‐batch reproducibility of P(S‐co‐BA) with 78.7 mol% of styrene and 21.3 mol% of butyl acrylate via EP in 3 metric‐ton (MT) pilot‐scale reactor. Polymerization efficiency, molecular, and physical characterization of the copolymers are examined using gravimetric analysis. Fourier transform infrared spectroscopy (FTIR), nuclear magnetic resonance (NMR), gel permeation chromatography (GPC), thermal gravimetry analysis (TGA), differential scanning calorimeter (DSC), viscometer, capillary rheometer, particle size analyzer (including dynamic light scattering and laser diffraction techniques), and scanning electron microscope (SEM). The gravimetric analysis on the monomer conversion reveals that the polymerization in 3‐MT reactor is efficient with 100% conversion. Besides, 1H‐NMR results reveal that the styrene‐to‐butyl acrylate mole ratio of the copolymer is of close approximation of the monomer feed amount while FTIR is a rather convenient quality control (QC) tool for batch‐to‐batch reproducibility on the copolymer molecular structured. The physical characteristic of [P(S‐co‐BA)] for all five batches are considered reproducible.

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“…Model‐based optimization of industrial emulsion (co)polymerization reactors using real plant data is relatively scarce in the open literature. Few exceptions—dealing with off‐line process intensification or virtual MPC—include product quality control, minimization of batch time in semibatch production of carboxylated styrene‐butadiene rubber (XSBR) and of polyvinyl acetate in a reactor with evaporative cooling, and minimization of off‐spec product during grade transitions in continuous production of SBR . Industrial semibatch solution polymerization process producing a liquid polymer with a low molecular weight and therefore enabling to sense the product quality by viscosity measurements was subjected to online optimizing control by Finkler et al…”

Section: Introductionmentioning

confidence: 99%

Bringing the On‐Line Control and Optimization of Semibatch Emulsion Copolymerization to the Pilot Plant

Zubov

Naeem²,

Hauger

et al. 2017

Macro Reaction Engineering

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Due to hardening competition and increased focus on resource efficiency, efforts are made to develop advanced industrial optimization and control systems with the goal to shift the (semi‐)batch production from recipe‐based to a state‐based approach. This study illustrates the steps needed for the implementation of optimization and on‐line control of semibatch emulsion copolymerization involving the development of process model, its validation and connection with control software, and the realization at pilot plant scale. The process model must be fast and robust enough to provide estimation of the process trajectory reliably and quickly. Moreover, in connection with nonlinear model predictive control (NMPC), the model has to be able to learn from the process and to update parameter values in real time, e.g., due to change of reactor jacket heat transfer. The Cybernetica CENIT software is employed for NMPC. The industrial pilot‐scale semibatch emulsion copolymerization of four comonomers (two of them water soluble) is used for the demonstration of NMPC functionality for: (i) reactor temperature control, (ii) minimization of batch time while preserving product quality, and (iii) minimization of batch duration with desired simultaneous shift in product quality.

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Modelling, simulation and control of an industrial, semi-batch, emulsion-polymerization reactor

Cited by 35 publications

References 23 publications

Models in the Polymer Industry: What Present? What Future?

Models in the Polymer Industry: What Present? What Future?

Batch‐to‐Batch Reproducibility Studies of Pilot‐Scale Emulsion Polymerization of Poly(styrene‐co‐butyl acrylate)

Bringing the On‐Line Control and Optimization of Semibatch Emulsion Copolymerization to the Pilot Plant

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