Model development and control of an auto-refrigerated polystyrene polymerization reactor

Abstract

Dynamic model development and control of an existing operating industrial continuous bulk free radical styrene polymerization process are carried out to evaluate the performance of auto-refrigerated CSTRs (continuous stirred tank reactors). One of the most difficult tasks in polymerization processes is to control the high viscosity reactor contents and heat removal. In this study, temperature control of an auto-refrigerated CSTR is carried out using an alternative control scheme which makes use of a vacuum system connected to the condenser and has not been addressed in the literature (i.e. to the best of our knowledge). The developed model is then verified using some experimental data of the real operating plant. To show the heat removal potential of this control scheme, a common control strategy used in some previous studies is also simulated. Simulation results show a faster dynamics and superior performance of the first control scheme which is already implemented in our operating plant. Besides, a nonlinear model predictive control (NMPC) is developed for the polymerization process under study to provide a better temperature control while satisfying the input/output and the heat exchanger capacity constraints on the heat removal. Then, a comparison has been also made with the conventional proportional-integral (PI) controller utilizing some common tuning rules. Some robustness and stability analyses of the control schemes investigated are also provided through some simulations. Simulation results clearly show the superiority of the NMPC strategy from all aspects.

Tube‐based batch model predictive control for polystyrene polymerization reaction process

“…At present, polystyrene is widely used in the chemical, manufacturing, construction, and electrical industries due to its excellent chemical resistance, thermal stability, mechanical durability, and electrical insulation. [1][2][3] However, the modeling and control of the polystyrene polymerization reaction process remains a difficult research area, primarily due to the processes' complex reaction kinetics, highly nonlinear nature, and interactivity between process variables. 4 One of the important objectives of the polystyrene polymerization reaction process is to ensure that the enduse polystyrene products have the desired properties for a specific application, such as the molecular weight distribution, chain lengths, and monomer conversion.…”