Scheme for Time-optimal Operation of Semi-batch Emulsion Polymerization Reactors

Realization of Online Optimizing Control in an Industrial Polymerization Reactor

“…Ongoing work concerns the implementation of the optimizing scheme with simultaneous temperature tracking and feed maximization. Tests with automatic monomer feed control using a direct scheme similar to (Finkler et al 2012 andPelz et al 2012) were already successfully performed at the real plant and provided a significant reduction of the duration of the batches. The main engineering effort went into the setup, parameter estimation and validation of the model that is used in the controller and in the development of a robust and reliable estimator.…”

“…For instance, in (Gesthuisen et al 2004) and (Mauntz 2010), strategies for the time-optimal operation of emulsion polymerizations that combine model-based state estimation and PI control are proposed. Recently, an optimizing scheme for semi-batch processes which only uses PI controllers was introduced in (Finkler et al 2012) and (Pelz et al 2012). Nonetheless, despite all the work that has been made over the last decades, the development of an optimizing control scheme that is capable to provide good temperature control and operate the batch as fast as possible is still a challenging task.…”

“…Moreover, preliminary tests of an optimizing scheme with simultaneous temperature tracking and monomer feed maximization were already performed at the real plant as well. These preliminary tests were realized by combining the model based temperature controller with a (non-model based) monomer feed controller that adjusts the monomer dosage so that the cooling power is high but the cooling valve is not saturated, as it is proposed in (Finkler et al 2012) and (Pelz et al 2012). This controller implements tracking of the optimality conditions without an explicit process model.…”

Closed-Loop Multitarget Optimization for Discovery of New Emulsion Polymerization Recipes

“…Closed loop control of emulsion polymerization industrial plants requires a fully predictive model. 18 − 23 However, many industrial plants are run on the basis of predetermined recipes mainly due to the absence of robust physical models. Inspired by the huge impact copolymerization of styrene and butyl acrylate has in industry and research, 24 − 30 we studied this two-monomer system as an example of a complex process leading to a functional product.…”

“…It is a complex multiphase system consisting of monomer droplets, latex particles, and continuous aqueous phase and is strongly influenced by temperature, pH, surfactant, and inhibitor concentrations and types, ratio of monomers, and so forth. Closed loop control of emulsion polymerization industrial plants requires a fully predictive model. − However, many industrial plants are run on the basis of predetermined recipes mainly due to the absence of robust physical models. Inspired by the huge impact copolymerization of styrene and butyl acrylate has in industry and research, − we studied this two-monomer system as an example of a complex process leading to a functional product.…”