Dynamic Optimization of Molecular Weight Distribution in Industrial Batch Polymerization

Market demand for high-performance polymers often requires flexibility to customize product properties with a high degree of consistency. Batch processes are often used to produce high-performance polymers due to their flexibility. The product properties are related to molecular weight distribution (MWD). However, due to the nature of dynamic within batch and batch-to-batch variability, controlling MWD is challenging, leading to inconsistent product properties. Additionally, changes in polymer properties often require cumbersome formulation development, which in practice is not flexible enough to meet downstream requirements for polymer property customization. To address these issues, a mechanistic model of an industrial batch polymerization process is developed, and a dynamic optimization problem is designed on this model. Within the framework of dynamic optimization, it is demonstrated that the MWD can be adjusted by manipulating the initial concentration and flow rate of the chain transfer agent at a constant reaction temperature, which provides the basis and direction for the subsequent development of control strategies to the MWD.