Modeling of a solution polymerization reactor operating in semi-batch mode for polymethyl methacrylate production

The severe consequences of thermal runaways, make process optimization of paramount importance for free radical polymerization reactors, in order to maximize in an integrated way their safety and productivity. Generally, this optimization is performed by simulation, for the sake of safety and cost. Today, the literature contains several models of free radical polymerization reactors in general; and methyl methacrylate (MMA) polymerization reactors, in particular. Although, MMA polymerization is commonly performed in semi-batch reactors at industrial level, most of the available models focus on batch reactors; while, the semi-batch reactor models are much scarcer. In this work, a model of a MMA solution polymerization batch reactor was modified in order to generalize it to semi-batch operation. The developed semi-batch model was used here for studying the effect of different operation conditions (feeding flow rate, initiator load, monomer initial load, and reactor temperature) on the quality characteristics of the produced polymer and on the safety and productivity of the polymerization reactor. The developed model can be used to optimize the operation conditions of a semi-batch reactor so that the final product quality meets the application requirements, while maintaining the reactor within its safe-operation envelope, and maximizing its productivity. • A model of a semi-batch reactor for MMA polymerization was proposed. • The model simulates the evolution of the moments of the polymer size distribution. • The model allows to assess the safety and productivity of the reactor. • The model was used for studying the effect of different operation conditions. • The model can be used to optimize the operation conditions of a semi-batch reactor.