Productivity optimization of an industrial semi-batch polymerization reactor under safety constraints

In this work the operation of an industrial semi-batch reactor is optimized . In the reactor a strongly exothermic polymerization reaction takes place and the objective is to minimize the duration of the batch time. Various op erational as well as quality and safety related constraints have to be met during the batch and at its final time. Tn particular, a cooling system fai lure is taken into account explicitly since the temperature rise in this ca se must not exceed a corresponding limit. The optimization is based on a de tailed process model derived from first principles. A reduced model is deve loped for optimization and trajectories for the operational variables feed flowrate and reactor temperature are calculated. The results show that sign ificant reductions of the batch time are possible and that their extent dep end on the formulated safety constraints. For a selected case the obtained optimal trajectories are verified experimentally in laboratory and producti on scale. (C) 2000 Elsevier Science Ltd. All rights reserved.