Continuous polymerization, reactor control optimization

Lewin and Bogle (1996) This paper concerns the optimal operation and controllability of a continuous polymerization reactor. 

A continuous bulk polymerization process with three reaction zones in series has been developed. The degree of polymerization increases from the first reactor to the third reactor. Examples of suitable reactors include continuous stirred tank reactors, stirred tower reactors, axially segregated horizontal reactors, and pipe reactors with static mixers. The continuous stirred tank reactor type is advantageous, because it allows for precise independent control of the residence time in a given reactor by adjusting the level in a given reactor. Thus, the residence time of the polymer mixtures can be independently adjusted and optimized in each of the reactors in series (8). 

The second part deals with how polymers are prepared from monomers and the transformation of polymers into useful everyday articles. It starts with a discussion of the various polymer preparation methods with emphasis on reaction mechanisms and kinetics. The control of molecular weight through appropriate manipulation of the stoichiometry of reactants and reaction conditions is consistently emphasized. This section continues with a discussion of polymer reaction engineering. Emphasis is on the selection of the appropriate polymerization process and reactor to obtain optimal polymer properties. The section terminates with a discussion of polymer additives and reinforcements and the various unit operations in polymer processing. Here again, the primary focus is on how processing conditions affect the properties of the part produced. 

In general, the optimization of polymerization processes [2] focuses on the determination of trade-offs between polydispersity, particle size, polymer composition, number average molar mass, and reaction time with reactor temperature and reactant flow rates as manipulated variables. Certain approaches [3] apply nonhnear model predictive control and online, nonlinear, inferential feedback control [4] to both continuous and semibatch emulsion polymerization. The objectives include the control of copolymer composition. 

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