The manufacturing
industry is challenged by increasing costs
of scarce resources, rapid change, and tight competition in global
markets, and the need for efficient and sustainable process design
and operating strategies. Addressing these challenges has been the
focus of process intensification (PI). Polymerization processes face
the additional challenge of meeting tight product specifications,
which are dictated by the demands of high quality and advanced materials.
Meeting these specifications requires the incorporation of complex
molecular weight distribution (MWD) models based on population balances
of all the polymer chains. Addressing these challenges through process
intensification requires the development and application of efficient,
robust, and powerful optimization strategies and modeling frameworks,
leading to an essential strategy for process intensification of polymerization
systems. This survey presents the development and application of novel
optimization strategies for model development, process synthesis and
design, and the operation of polymer processes. The effectiveness
of these optimization-based approaches will be demonstrated on a slurry
process for high density polyethylene (HDPE), where significant advances
in process intensification have been realized. Future directions are
given, with the aim of benefiting both research and application in
this field.