Optimal policies for BMA polymerization in nonisothermal batch reactor

In this paper, the optimal policies for bulk polymerization of n‐butyl methacrylate (BMA) are determined in a nonisothermal batch reactor. Four objectives are realized for BMA polymerization based on a detailed process model. The objectives are: (i) maximization of monomer conversion in a specified operation time, (ii) minimization of operation time for a specified, final monomer conversion, (iii) maximization of monomer conversion for a specified, final number average polymer molecular weight, and (iv) maximization of monomer conversion for a specified, final weight average polymer molecular weight. For each objective, the optimal temperature policy of heat‐exchange fluid inside reactor jacket is determined. The temperature of the heat‐exchange fluid is considered as a function of a specified variable. Necessary equations are provided to suitably transform the process model in terms of a specified variable other than time, and to evaluate the elements of Jacobian to help in the accurate solution of the process model. A genetic algorithm‐based optimal control method is applied to realize the objectives. The resulting optimal policies of this application reveal considerable improvements in the batch production of poly(BMA). © 2006 Wiley Periodicals, Inc. J Appl PolymSci 102: 2799–2809, 2006     

On‐line determination of the conversion in a styrene bulk polymerization batch reactor using near‐infrared spectroscopy

A fast on‐line method for measuring the monomer conversion of a styrene batch polymerization reaction with near‐infrared spectroscopy (NIR) has been developed. Multivariate calibration was performed, using polymer samples having temperatures around the set point of the batch reactor (75–85°C) and monomer conversions up to 35%. The calibration model was built in such a way that the effect of the temperature on the predicted conversion of the sample was minimized. The method was validated in a number of batch runs. In these runs, the batch temperature and molar mass distributions of the polymer were varied. At‐line size‐exclusion chromatography was used as a reference method for measuring the monomer conversion. Results show that on‐line conversion monitoring with NIR offered overall an excellent accuracy (～ 0.32% conversion). For high and low monomer conversions a small bias in the predicted conversion is present. The method proved to be insensitive to both relative large changes (10°C) of the batch temperature and to considerable changes of the molar mass distribution of the polymer. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 90–98, 2002; DOI 10.1002/app.10241     

Multiobjective dynamic optimization of an industrial nylon 6 semibatch reactor using genetic algorithm

The nondominated sorting genetic algorithm (NSGA) is adapted and used to obtain multiobjective Pareto optimal solutions for three grades of nylon 6 being produced in an industrial semibatch reactor. The total reaction time and the concentration of an undesirable cyclic dimer in the product are taken as two individual objectives for minimization, while simultaneously requiring the attainment of design values of the final monomer conversion and for the number-average chain length. Substantial improvements in the operation of the nylon 6 reactor are indicated by this study. The technique used is very general in nature and can be used for multiobjective optimization of other reactors. Good mathematical models accounting for all the physicochemical aspects operative in a reactor (and which have been preferably tested on industrial data) are a prerequisite for such optimization studies. © 1998 John Wiley & Sons, Inc. J Appl Polym Sci 69: 69–87, 1998     

Multiobjective optimization of an industrial nylon-6 semibatch reactor system using genetic algorithm

Multiobjective Pareto optimal solutions for three different grades of nylon-6 produced in an industrial semibatch reactor are obtained by using the adapted Nondominated Sorting Genetic Algorithm (adapted NSGA). The two objective functions minimized are the total reaction time and the concentration of undesirable cyclic dimer in the product, while simultaneously attaining desired values of the monomer conversion and the number average chain length. The control variables used are the fractional valve opening f(t) and the jacket fluid temperature T_J. The study shows a marked improvement over current industrial operation. It is found that the optimal values of the cyclic dimer concentration in the product are worse (higher) when the reactor-control valve system is studied than when the reactor is considered alone. This is because the control valve leads to additional constraints. The technique used is quite general and can be used to study other reactor systems as well. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 73: 729–739, 1999     

Simulation and application of response surface methodology to a nylon‐6 hydrolytic polymerization in a semibatch reactor

This work presents an experimental design methodology combined with computational simulation to correlate the influence of operational conditions and reactants charge in the numeric average molecular weight (MWN) as well as on monomer conversion (X_CL), for the hydrolytic polymerization of nylon‐6 in a semibatch reactor. It evaluated the reaction temperature, the pressure profile, and the proportion of reactants in the charge. Experimental design was used to screen the most statistically significant variables and to develop a reliable predictive model for each response. The combined use of the models can be applied for process optimization, by establishing MWN and maximum X_CL as objective functions. Responses surface allowed the visualization of the responses behavior when changing the independent variables and therefore to identify the optimal tendencies. This work demonstrates that such methodology can be applied for optimization of complex processes like the hydrolytic polymerization of nylon‐6. This polymerization has many side reactions occurring at the same time, which are sensitive to different profiles of pressure and temperature that are applied. This evaluation is quite interesting as such profiles are necessary to perform the several polymerization steps and have a significant impact on product characteristics and therefore in its applications. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Dehydrogenation of 11α‐hydroxy‐16α, 17‐epoxyprogesterone by encapsulated Arthrobacter simplex cells in an aqueous/organic solvent two‐liquid‐phase system

BACKGROUND: Arthrobacter simplex cells immobilised in sodium cellulose sulfate/poly‐dimethyl‐diallyl‐ammonium chloride microcapsules were used for the microbial dehydrogenation of 11α‐hydroxy‐16α,17‐epoxyprogesterone to 11α‐hydroxy‐16α,17α‐epoxypregn‐1,4‐diene‐3,20‐dione in an aqueous/organic solvent two‐liquid‐phase system, which is a key reaction in the production of glucocorticoid pharmaceuticals. The aim of the study was to establish a suitable aqueous/organic solvent two‐liquid‐phase system for performing semi‐continuous production in an airlift loop reactor by encapsulated A. simplex cells with the addition of suitable surfactants to achieve a higher yield of the product. RESULTS: n‐Hexane was selected as the most suitable organic solvent. In optimised Tween‐80 emulsion feed mode the conversion in the airlift loop reactor was as high as 97.54% when the time of reaction was 2 h, and the reaction time was greatly shortened. In semi‐continuous production the cultivation with immobilised cells was carried out for five batches in total. The conversion in each batch was above 95% and the enzymatic activity still remained quite high after five batches of biotransformation. CONCLUSION: The results showed that performing the conversion by this method shortened the reaction time and increased the productivity, thus demonstrating the great potential of the method for the dehydrogenation of 11α‐hydroxy‐16α,17‐epoxyprogesterone. Copyright © 2008 Society of Chemical Industry     

Poly(dimethylsiloxane‐b‐styrene) diblock copolymers prepared by reversible addition‐fragmentation chain transfer polymerization: Kinetic model

Well‐defined polydimethylsiloxane‐block‐polystyrene (PDMS‐b‐PS) diblock copolymers were prepared by reversible addition‐fragmentation chain transfer (RAFT) polymerization using a functional PDMS‐macro RAFT agent. The RAFT polymerization kinetics was simulated by a mathematical model for the RAFT polymerization in a batch reactor based on the method of moments. The model described molecular weight, monomer conversion, and polydispersity index as a function of polymerization time. Good agreements in the polymerization kinetics were achieved for fitting the kinetic profiles with the developed model. In addition, the model was used to predict the effects of initiator concentration, chain transfer agent concentration, and monomer concentration on the RAFT polymerization kinetics. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

A preliminary evaluation of a continuous‐flow reactor for liquid–liquid–solid phase‐transfer catalyzed synthesis of n‐butyl phenyl ether

This study evaluates the feasibility of using a continuous‐flow stirred vessel reactor (CFSVR) to synthesize n‐butyl phenyl ether (ROPh) from n‐butyl bromide (RBr) and sodium phenolate (NaOPh) by liquid–liquid–solid phase‐transfer catalysis (triphase catalysis). The factors affecting the preparation of triphase catalysts, the etherification reaction in a batch reactor, and the performance in a CFSVR were investigated. The kinetic study with a batch reactor indicated that when the initial concentration of NaOPh or RBr was high, the conversion of RBr would depend on the initial concentration of both RBr and NaOPh. The reaction can be represented by a pseudo‐first‐order kinetic model when the concentration of NaOPh is in proper excess to that of RBr, and the apparent activation energy is 87.8 kJ mol^?1. When the etherification reaction was carried out in the CFSVR, the catalyst particles did not flow out of the reactor, even at a high agitation speed. The conversion of RBr in the CFSVR was, as predicted, lower than that in the batch reactor, but was higher than the theoretical value because the dispersed phase is not completely mixed. Copyright © 2004 Society of Chemical Industry     

Experimental study of the spontaneous thermal homopolymerization of methyl and n‐butyl acrylate

This article presents an experimental study of the spontaneous thermal homopolymerization of methyl acrylate (MA) and n‐butyl acrylate (nBA) in the absence of any known added initiators at 120 and 140°C in a batch reactor. The effects of the solvent type, oxygen level, and reaction temperature on the monomer conversion and polymer average molecular weights were investigated. Three solvents, dimethyl sulfoxide (DMSO; polar, aprotic), cyclohexanone (polar, aprotic), and xylene (nonpolar) were used. The spontaneous thermal polymerization of MA and nBA in DMSO resulted in a lower conversion and higher average molecular weights in comparison to polymerization in cyclohexanone and xylene under the same conditions. The highest final conversion of both monomers was obtained in cyclohexanone. The high polymerization rate in cyclohexanone was most likely due to an additional initiation mechanism where cyclohexanone complexed with the monomer to generate free radicals. Bubbling air through the mixture led to a higher monomer conversion during the early stage of the polymerization and a lower polymer average molecular weight in xylene and cyclohexanone; this indicated the existence of a distinct behavior between the air‐ and nitrogen‐purged systems. Matrix‐assisted laser desorption/ionization time‐of‐flight analysis of the polymer samples taken from nitrogen‐bubbled batches did not reveal fragments from initiating impurities. On the basis of the identified families of peaks, monomer self‐initiation is suggested as the principal mode of initiation in the spontaneous thermal polymerization of MA and nBA at temperatures above 100°C. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Single‐ and two‐step procedures of AGET emulsion ATRP of methyl methacrylate in a well‐mixed batch reactor

This study investigates the atom transfer radical emulsion polymerization of methyl methacrylate in a 2 L well‐mixed stirred batch reactor using activators generated by electron transfer as the initiation technique. The polymerization was carried out with ethyl‐2‐bromoisobutyrate as the initiator, copper bromide with 4,4′‐di‐5‐nonyl‐2,2′‐bipyridine as the catalyst system, Brij 98 as the surfactant, and ascorbic acid as the reducing agent. The reaction was carried out at constant temperature in the range of 50 to 70 °C under a blanket of nitrogen to minimize the presence of air in the system. Polymerizations were carried out according to single‐step and two‐step procedures. The coagulation was found to be a major problem, especially at high monomer conversion. However, adding more surfactant and lowering the reaction temperature weakened the effect of the coagulation but at the expense of the low monomer conversion. Measurement of molecular weight distribution and ? using gel permeation show that the two‐step techniques produced polymers with living features of atom transfer radical emulsion polymerization much better than those in the single‐step procedure. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134 , 45308.     

Highly efficient reversible addition–fragmentation chain‐transfer polymerization in ethanol/water via flow chemistry

Utilization of a flow reactor under high pressure allows highly efficient polymer synthesis via reversible addition–fragmentation chain‐transfer (RAFT ) polymerization in an aqueous system. Compared with the batch reaction, the flow reactor allows the RAFT polymerization to be performed in a high‐efficiency manner at the same temperature. The adjustable pressure of the system allows further elevation of the reaction temperature and hence faster polymerization. Other reaction parameters, such as flow rate and initiator concentration, were also well studied to tune the monomer conversion and the molar mass dispersity (?) of the obtained polymers. Gel permeation chromatography, nuclear magnetic resonance (NMR), and Fourier transform infrared spectroscopies (FTIR) were utilized to monitor the polymerization process. With the initiator concentration of 0.15 mmol L^?1, polymerization of poly(ethylene glycol) methyl ether methacrylate with monomer conversion of 52% at 100 °C under 73 bar can be achieved within 40 min with narrow molar mass dispersity (D) ? (<1.25). The strategy developed here provides a method to produce well‐defined polymers via RAFT polymerization with high efficiency in a continuous manner. © 2017 Society of Chemical Industry     

Polynomial ARMA model identification for a continuous styrene polymerization reactor using on‐line measurements of polymer properties

The multiinput–multioutput identification for a continuous styrene polymerization reactor using a polynomial ARMA model is carried out by both simulation and experiment. The pseudorandom multilevel input signals are applied for model identification in which input variables are the jacket inlet temperature and the feed flow rate, whereas the output variables are the monomer conversion and the weight‐average molecular weight. The use of a polynomial ARMA model for identification of the multivariable polymerization reaction system is validated by simulation study. For the experimental corroboration, correlations are developed to convert the on‐line measurements of density and viscosity of the reaction mixture to the monomer conversion and the weight‐average molecular weight. The on‐line values of the conversion and weight‐average molecular weight turn out to be in good agreement with the off‐line measurements. Despite the complex and nonlinear features of the polymerization reaction system, the polynomial ARMA model is found to satisfactorily describe the dynamic behavior of the polymerization reactor. Therefore, one may apply the polynomial ARMA model to the optimization and control of polymerization reactor systems. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 76: 1889–1901, 2000     

Modeling of the sheet‐molding process for poly(methyl methacrylate)

The sheet‐molding process for the production of poly(methyl methacrylate) (PMMA) involves an isothermal batch reactor followed by polymerization in a mold (the latter is referred to as a “sheet reactor”). The temperature at the outer walls of the mold varies with time. In addition, due to finite rates of heat transfer in the viscous reaction mass, spatial temperature gradients are present inside the mold. Further, the volume of the reaction mass also decreases with polymerization. These several physicochemical phenomena are incorporated into the model developed for this process. It was found that the monomer conversion attains high values of near‐unity in most of the inner region in the mold. This is because of the high temperatures there, since the heat generated due to the exothermicity of the polymerization cannot be removed fast enough. However, the temperature of the mold walls has to be increased in the later stages of polymerization so that the material near the outer edges can also attain high conversions of about 98%. This would give PMMA sheets having excellent mechanical strength. The effects of important operating (decision) variables were studied and it was observed that the heat‐transfer resistance in the mold influences the spatial distribution of the temperature, which, in turn, influences the various properties (e.g., monomer conversion, number‐average molecular weight, and polydispersity index) of the product significantly. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 81: 1951–1971, 2001     

Experimental investigation of vinyl chloride polymerization at high conversion—reactor dynamics

A series of suspension polymerizations of vinyl chloride monomer (VCM) was carried out in a 5-L pilot plant reactor over the temperature range, 40–70°C. The reactor pressure and monomer conversion were monitored simultaneously every 7–8 min. The critical conversion X_f, at which the liquid monomer phase is consumed, was considered to occur when the reactor pressure fell to 98% of the vapor pressure of VCM for suspension at the polymerization temperature. The reactor model predictions of pressure are in excellent agreement with the experimental data over the entire conversion and temperature ranges studied. The mechanism of reactor pressure development for VCM suspension polymerization is discussed herein in some detail. For isothermal batch polymerization, the reactor pressure falls in two stages due to the effect of polymer particle morphology on pressure drop. The first stage is due to the volume increase of the vapor phase as a result of volume shrinkage due to conversion of monomer to polymer. The monomer phase is not yet consumed at this stage, but it is trapped in the interstices between primary particles creating a mass transfer resistance; therefore, the reactor pressure drops slowly. The second stage is due to both the volume increase of the vapor phase and to the monomer in the vapor phase diffusing into the polymer phase because of the subsaturation condition with respect to monomer in the polymer phase. The reactor pressure drops dramatically with an increase in monomer conversion at this stage. The present model can be used to predict reactor dynamics during suspension polymerization under varying temperature and pressure conditions.     

Dynamic optimization of an industrial semi-batch nylon 6 reactor with end point constraints and stopping conditions

In this study, optimal vapor release rate (or pressure) histories have been generated for an industrial semi-batch nylon 6 reactor using Pontryagin's minimum principle. The batch time has been taken as the objective function, which is to be minimized. The pressure is constrained to lie between a lower and an upper limit. The temperature, a state variable, is also constrained to lie between 220°C and 270°C in order to ensure single-phase polymerization. Optimization has been carried out with a single end-point constraint (on monomer conversion) and a stopping condition (obtaining a product having a desired degree of polymerization, μ_n). Techniques have been developed to overcome the discontinuities present in the model, as well as to take care of state variable constraints. The effects of various physical and computational variables on the optimal pressure history and the corresponding batch time have been studied. It is found that the optimal batch time is almost 50% of the industrial value used currently. Interestingly, the optimal pressure history is quite similar qualitatively with the current practice though quantitatively there is a significant difference. Improvements in reactor operation along these lines have been reported. © 1996 John Wiley & Sons, Inc.     

Continuous‐Flow Di‐N‐Alkylation of 1H‐Benzimidazole in a Fixed‐Bed Reactor

A new process for a continuous‐flow di‐N‐alkylation of 1H‐benzimidazole to 1H‐benzimidazole‐3‐ium iodide by methylene iodide in the presence of potassium carbonate in a fixed‐bed reactor is presented. The synthesis was transferred from batch to continuous operation with similar yields and conversion rates. Moreover, the influence of temperature and residence time in the continuous flow setup was characterized; optimized conditions led to a doubling of yield. In addition, the continuous flow allowed for a better control of the two‐step reaction by adding an additional tube reactor after the fixed bed that further enhanced the overall performance. With this, the continuous‐flow system presented itself as superior due to higher available temperatures and a better controllability.     

TEMPO‐controlled radical suspension polymerization of poly(styrene)‐block‐poly(styrene‐co‐acrylonitrile) and poly(styrene)‐block‐poly(styrene‐co‐butyl methacrylate)

Suspension polymerization expands the study of controlled radical polymerization to high conversions and is known as a method to synthesize polymers with high molecular weights. The radical block copolymerizations of styrene (S) and acrylonitrile (AN) or butyl methacrylate (BUMA) controlled by 2,2,6,6‐tetramethylpiperidine‐N‐oxyl (TEMPO) was performed in an oil/water pressure reactor system at a temperature of 125°C. TEMPO‐terminated styrene homopolymer was employed as macroinitiator. The systems were examined by varying the composition of the monomer mixture at a constant reaction time, as well as by varying the reaction time for a characteristic monomer composition to get all of the possible conversion range. The solubility effects of acrylonitrile in the suspension medium were considered. Furthermore, the yield of the reaction was improved through initiator addition by taking control of the reaction. The polymerizations could proceed under control up to a conversion of 80–90%. By using the copolymerization equations, the solubility of pure acrylonitrile in the suspension medium could be calculated and was found to be 8 wt.‐%.     

Application of optimal temperature trajectory to batch PMMA polymerization reactor

A mathematical model is developed for the polymerization of methyl methacrylate (MMA) in a batch reactor. The model includes chain transfers to the monomer and solvent and termination by both combination and disproportionation and also takes into account the density change of the reactor contents and the gel effect. The usual pseudo-steady-state assumption is relaxed here. The validity of the proposed model is tested by an isothermal experiment of batch PMMA polymerization. Indeed, the experimental results show that the proposed model can describe the real polymerization system very well in view of both monomer conversion and average molecular weights. The optimal control theory is applied together with Pontryagin's minimum principle to calculate the optimal temperature trajectory for a batch polymerization reactor system which would lead to a polymer product having the desired properties set a priori. The performance index of the control system is composed of three factors—the desired monomer conversion and number- and weight-average molecular weights. The desired values of number- and weight-average molecular weights are obtained at a specified monomer conversion within acceptable error ranges. Control experiments are conducted to track the optimal temperature trajectory obtained from the model and the results are found to be in good agreement with the desired values. © 1998 John Wiley & Sons, Inc. J Appl Polym Sci 69: 59–68, 1998     

Hydrogel characteristics of a novel temperature‐sensitive polymer,poly(N‐2‐methoxyisopropylacrylamide)

In this study, a novel temperature‐sensitive polymer, poly(N‐2‐methoxyisopropylacrylamide), PNMIPA, in the crosslinked hydrogel form was obtained. The monomer, N‐2‐methoxyisopropylacrylamide (NMIPA) was synthesized by the nucleophilic substitution reactions of acryloyl chloride with 2‐methoxyisopropylamine. Hydrogel matrix of PNMIPA was obtained by the bulk polymerization method. The bulk polymerization experiments were performed at +4°C, by using N,N‐methylenebisacrylamide (MBA) as crosslinker, polyethyleneglycol (PEG) 4000 as diluent, and potassium persulfate (KPS) and tetramethylethylenediamine (TEMED) as the initiator and accelerator, respectively. The same polymerization procedures were applied by changing monomer, initiator, crosslinker and diluent concentrations in order to obtain crosslinked gel structures having different temperature–sensitivity properties. The equilibrium swelling ratio of PNIMPA gel matrices at constant temperature increased with increasing initiator concentration and decreasing monomer concentration. The use of PEG 4000 as diluent in the gel synthesis resulted in about two times increase in equilibrium swelling ratios in the low temperature region. A decrease in the equilibrium swelling ratios of gel matrices started at 30°C and the decrease became insignificant at 55°C. Temperature‐sensitivities were determined in two different media. Distilled water medium was used in order to observe the temperature‐sensitivity of the gel clearly and the phosphate buffer medium was used in order to represent the temperature‐sensitive swelling behavior of the gel when it is used in biological media. Step effect was applied on ambient temperature in two opposite directions in order to examine the dynamic swelling and shrinking behaviors of the gels. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

High‐frequency welding of thermoplastic LLDPE/PA 6/PE‐g‐MAH ternary blends

High frequency (HF) welding of linear low density polyethylene (LLDPE) melt blends with polyamide 6 (PA6) was done at 27.12 MHz using maleic anhydride grafted polyethylene (PE‐g‐MAH) as compatibilizer. HF welding was not possible for the blends at room temperature, but possible at higher temperatures (50, 80°C) although the maximum relaxation frequency was lower than the operating frequency. Greater dielectric constant, dissipation factor, and welding performance were obtained when PA 6 was premixed with PE‐g‐MAH rather than the one‐shot process where all the components were mixed simultaneously. This was interpreted in terms of lowered viscosity of PA 6 phase, which encapsulates the flow effectively and provides great skin effect. Also, the peeling force of resin–resin was greater than resin–nylon mesh due to the higher melting temperature and vacancy of nylon mesh. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008