Multi-rate model predictive control of particle size distribution in a semibatch emulsion copolymerization reactor

A multi-rate model predictive controller algorithm is presented for the in-batch closed-loop control of the full particle size distribution (PSD) in a semibatch emulsion copolymerization system. The lack of frequent measurements of the PSD and the measurement delay of these measurements are addressed through the use of frequent density measurements from which the current conditions of the system are estimated. The high dimensionality of the discretized full PSD is reduced by the use of model order reduction based on principal component analysis. This method effectively reduces the size of the problem while preserving the main characteristics of the population balance system. Disturbances that perturb the surfactant and monomer amounts inside the semibatch vinyl acetate–butyl acrylate reactor are considered to demonstrate the performance of the proposed control algorithm.