Optimization of Emulsion Copolymerization Reactions. Experimental Validation

−− Time optimal monomer and reactor temperature set-point profiles were computed and implemented experimentally for the control of copolymer composition and minimization of reaction time in emulsion copolymerization systems. Iterative Dynamic Programming (IDP) was used for the offline calculation of the optimal profiles. This approach can deal with constrained optimization of systems described by complex mathematical models, as those needed for the emulsion copolymerization. The optimization procedure was applied to vinyl acetate / butyl acrylate emulsion copolymerization under industrial-like conditions, which includes safety constraints normally found in the operation of large-scale reactors. The dynamics of the reactor heat exchange system were also taken into account in the mathematical model. The optimal trajectories obtained by the IDP procedure were implemented in a jacketed reactor with automated control of temperature and monomers feed flow rates. The realtime implementation of the optimal trajectories was successfully carried out resulting in a significant reduction in reaction time and the production of homogeneous copolymer composition. Keywords−− Semicontinuous reaction; Optimal trajectories; Emulsion polymerization, Iterative Dynamic Programming.