Advanced Monitoring and Control of Multi-monomer System in Emulsion Polymerization

Abstract

A control framework was developed for real-time implementation of optimal control of emulsion polymerization with multiple monomers by integrating model-based algorithms with software engines. The developed system was applied for controlling conversion, particle size, molar mass, and polymer composition using model predictive control (MPC) based on mechanistic models for emulsion polymerization. The control formulation was extended to account for existing process constraints on the input, input moves, and solids content. On experimental testing, the developed control scheme was found to achieve the desired objectives without violating the process constraints and showed good robustness in rejecting disturbances. Improvements in the process operation and polymer property control were noted on implementing the developed multi-variable MPC for molar mass and product composition. The system facilitated efficient control of fundamental polymer attributes with semi-batch operation.A constrained model predictive control (MPC) was developed based on a multi-layer monitoring and regulatory system for emulsion polymerization of multiple monomers with batch and with semi-batch operation. Our design basis comprised mechanistic models for the multi-phase, multi-stage process for implementing the control of conversion, particle size, molar mass, and polymer composition using multi-platform software environment coordination. Experimental tests showed the achievement of desired objectives with good robustness and without violating the process constraints. Improvements in the process operation and product property control were noted on implementing the developed multi-variable MPC. Copyright © 2010 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.