On-line control of emulsion polymerization reactors: A perspective

Emulsion polymerization is the method of choice to produce a wide range of specialty waterborne polymer dispersions. These are multicharacteristic products that should meet conflicting application properties and are produced through a very complex process prone to suffer run-to-run irreproducibilities. In a scenario of increasing competition and smaller margins, achieving even more efficient production of better materials in a consistent, cost effective, safe, and environmentally friendly way will only be possible by implementing on-line control. However, on-line control is hindered by the lack of sensors able to monitor most of the characteristics of the emulsion polymers. This perspective discusses the state-of-the-art of the on-line control of emulsion polymerization reactors highlighting the achievements, challenges, and opportunities.