Optimization and non-linear control of a batch emulsion polymerization reactor

The optimal temperature policy which minimizes the terminal time in a batch emulsion polymerization reactor of styrene and alpha-methylstyrene was determined by means of orthogonal collocation techniques combined with a general non-linear programming method. The constraints concern the final latex properties and the thermal limitations of the pilot plant. An experimental validation has been realized. The optimal temperature profile was tracked using a non-linear geometric control technique which is particularly adapted to polymerization reactor control. An extended Kalman filter was used to estimate the non-measured state variables. Experimental results showed excellent agreement with predictions for this complex system. A good temperature tracking was observed and the product quality was well predicted and controlled. (C) 1999 Elsevier Science S.A. All rights reserved.