Dynamic optimization of the methylmethacrylate cell-cast process for plastic sheet production
Traditionally, the methylmethacrylate (MMA) polymerization reaction process for plastic sheet production has been carried out using warming baths. However, it has been observed that the manufactured polymer tends to feature poor homogeneity characteristics measured in terms of properties like molecu...
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| Published in | AIChE journal Vol. 55; no. 6; pp. 1464 - 1486 |
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| Main Authors | , , |
| Format | Journal Article |
| Language | English |
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Hoboken
Wiley Subscription Services, Inc., A Wiley Company
01.06.2009
Wiley American Institute of Chemical Engineers |
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| Abstract | Traditionally, the methylmethacrylate (MMA) polymerization reaction process for plastic sheet production has been carried out using warming baths. However, it has been observed that the manufactured polymer tends to feature poor homogeneity characteristics measured in terms of properties like molecular weight distribution. Nonhomogeneous polymer properties should be avoided because they give rise to a product with undesired wide quality characteristics. To improve homogeneity properties force-circulated warm air reactors have been proposed, such reactors are normally operated under isothermal air temperature conditions. However, we demonstrate that dynamic optimal warming temperature profiles lead to a polymer sheet with better homogeneity characteristics, especially when compared against simple isothermal operating policies. In this work, the dynamic optimization of a heating and polymerization reaction process for plastic sheet production in a force-circulated warm air reactor is addressed. The optimization formulation is based on the dynamic representation of the two-directional heating and reaction process taking place within the system, and includes kinetic equations for the bulk free radical polymerization reactions of MMA. The mathematical model is cast as a time dependent partial differential equation (PDE) system, the optimal heating profile calculation turns out to be a dynamic optimization problem embedded in a distributed parameter system. A simultaneous optimization approach is selected to solve the dynamic optimization problem. Trough full discretization of all decision variables, a nonlinear programming (NLP) model is obtained and solved by using the IPOPT optimization solver. The results are presented about the dynamic optimization for two plastic sheets of different thickness and compared them against simple operating policies. © 2009 American Institute of Chemical Engineers AIChE J, 2009 |
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| AbstractList | Abstract
Traditionally, the methylmethacrylate (MMA) polymerization reaction process for plastic sheet production has been carried out using warming baths. However, it has been observed that the manufactured polymer tends to feature poor homogeneity characteristics measured in terms of properties like molecular weight distribution. Nonhomogeneous polymer properties should be avoided because they give rise to a product with undesired wide quality characteristics. To improve homogeneity properties force‐circulated warm air reactors have been proposed, such reactors are normally operated under isothermal air temperature conditions. However, we demonstrate that dynamic optimal warming temperature profiles lead to a polymer sheet with better homogeneity characteristics, especially when compared against simple isothermal operating policies. In this work, the dynamic optimization of a heating and polymerization reaction process for plastic sheet production in a force‐circulated warm air reactor is addressed. The optimization formulation is based on the dynamic representation of the two‐directional heating and reaction process taking place within the system, and includes kinetic equations for the bulk free radical polymerization reactions of MMA. The mathematical model is cast as a time dependent partial differential equation (PDE) system, the optimal heating profile calculation turns out to be a dynamic optimization problem embedded in a distributed parameter system. A simultaneous optimization approach is selected to solve the dynamic optimization problem. Trough full discretization of all decision variables, a nonlinear programming (NLP) model is obtained and solved by using the IPOPT optimization solver. The results are presented about the dynamic optimization for two plastic sheets of different thickness and compared them against simple operating policies. © 2009 American Institute of Chemical Engineers AIChE J, 2009 Traditionally, the methylmethacrylate (MMA) polymerization reaction process for plastic sheet production has been carried out using warming baths. However, it has been observed that the manufactured polymer tends to feature poor homogeneity characteristics measured in terms of properties like molecular weight distribution. Nonhomogeneous polymer properties should be avoided because they give rise to a product with undesired wide quality characteristics. To improve homogeneity properties force-circulated warm air reactors have been proposed, such reactors are normally operated under isothermal air temperature conditions. However, we demonstrate that dynamic optimal warming temperature profiles lead to a polymer sheet with better homogeneity characteristics, especially when compared against simple isothermal operating policies. In this work, the dynamic optimization of a heating and polymerization reaction process for plastic sheet production in a force-circulated warm air reactor is addressed. The optimization formulation is based on the dynamic representation of the two-directional heating and reaction process taking place within the system, and includes kinetic equations for the bulk free radical polymerization reactions of MMA. The mathematical model is cast as a time dependent partial differential equation (PDE) system, the optimal heating profile calculation turns out to be a dynamic optimization problem embedded in a distributed parameter system. A simultaneous optimization approach is selected to solve the dynamic optimization problem. Trough full discretization of all decision variables, a nonlinear programming (NLP) model is obtained and solved by using the IPOPT optimization solver. The results are presented about the dynamic optimization for two plastic sheets of different thickness and compared them against simple operating policies. © 2009 American Institute of Chemical Engineers AIChE J, 2009 Traditionally, the methylmethacrylate (MMA) polymerization reaction process for plastic sheet production has been carried out using warming baths. However, it has been observed that the manufactured polymer tends to feature poor homogeneity characteristics measured in terms of properties like molecular weight distribution. Nonhomogeneous polymer properties should be avoided because they give rise to a product with undesired wide quality characteristics. To improve homogeneity properties force-circulated warm air reactors have been proposed, such reactors are normally operated under isothermal air temperature conditions. However, we demonstrate that dynamic optimal warming temperature profiles lead to a polymer sheet with better homogeneity characteristics, especially when compared against simple isothermal operating policies. In this work, the dynamic optimization of a heating and polymerization reaction process for plastic sheet production in a force-circulated warm air reactor is addressed. The optimization formulation is based on the dynamic representation of the two-directional heating and reaction process taking place within the system, and includes kinetic equations for the bulk free radical polymerization reactions of MMA. The mathematical model is cast as a time dependent partial differential equation (PDE) system, the optimal heating profile calculation turns out to be a dynamic optimization problem embedded in a distributed parameter system. A simultaneous optimization approach is selected to solve the dynamic optimization problem. Trough full discretization of all decision variables, a nonlinear programming (NLP) model is obtained and solved by using the IPOPT optimization solver. The results are presented about the dynamic optimization for two plastic sheets of different thickness and compared them against simple operating policies. [PUBLICATION ABSTRACT] Traditionally, the methylmethacrylate (MMA) polymerization reaction process for plastic sheet production has been carried out using warming baths. However, it has been observed that the manufactured polymer tends to feature poor homogeneity characteristics measured in terms of properties like molecular weight distribution. Nonhomogeneous polymer properties should be avoided because they give rise to a product with undesired wide quality characteristics. To improve homogeneity properties force-circulated warm air reactors have been proposed, such reactors are normally operated under isothermal air temperature conditions. However, we demonstrate that dynamic optimal warming temperature profiles lead to a polymer sheet with better homogeneity characteristics, especially when compared against simple isothermal operating policies. In this work, the dynamic optimization of a heating and polymerization reaction process for plastic sheet production in a force-circulated warm air reactor is addressed. The optimization formulation is based on the dynamic representation of the two-directional heating and reaction process taking place within the system, and includes kinetic equations for the bulk free radical polymerization reactions of MMA. The mathematical model is cast as a time dependent partial differential equation (PDE) system, the optimal heating profile calculation turns out to be a dynamic optimization problem embedded in a distributed parameter system. A simultaneous optimization approach is selected to solve the dynamic optimization problem. Trough full discretization of all decision variables, a nonlinear programming (NLP) model is obtained and solved by using the IPOPT optimization solver. The results are presented about the dynamic optimization for two plastic sheets of different thickness and compared them against simple operating policies. |
| Author | Flores-Tlacuahuac, Antonio Vílchis-Ramírez, Leopoldo Rivera-Toledo, Martín |
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| Keywords | Warming Temperature distribution Molecular weight distribution sheet reactor Non linear programming dynamic optimization Modeling Partial differential equation Optimization PDE Free radical polymerization Warm air Discretization PMMA Heating Production Homogeneity Kinetics Plastics Mathematical model Reactor Distributed parameter system Mathematical programming |
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| References_xml | – volume: 43 start-page: 7220 year: 2004 end-page: 7226 article-title: Modeling of the high‐temperature polymerization of methyl methacrylate. I. Review of existing models for the description of the gel effect publication-title: Ind Eng Chem Res. – volume: 5 start-page: 349 year: 1997 end-page: 355 article-title: Recent advances in the understanding of the gel effect in free radical polymerization publication-title: Trends Polym Sci. – volume: 45 start-page: 8539 year: 2006 end-page: 8553 article-title: Dynamic modeling and experimental validation of the mma cells cast process for plastic sheet production publication-title: Ind Eng Chem Res. – volume: 32 start-page: 882 year: 1993 end-page: 893 article-title: Optimal design and operation of batch reactors. II. 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Integration of Partial Differential Equations year: 1991 ident: e_1_2_8_24_2 contributor: fullname: Schiesser WE – ident: e_1_2_8_16_2 doi: 10.1080/10543414.1994.10744448 – ident: e_1_2_8_5_2 doi: 10.1016/S0098-1354(98)00294-4 – ident: e_1_2_8_15_2 doi: 10.1021/ie960481o – volume: 380 start-page: 3707 year: 1985 ident: e_1_2_8_8_2 article-title: Optimization of batch polymerization processes— narrowing the mwd. I. Model simulation publication-title: J Appl Polym Sci. contributor: fullname: Soong DS – ident: e_1_2_8_26_2 doi: 10.1021/ie034280d – ident: e_1_2_8_9_2 doi: 10.1021/ie00017a016 – ident: e_1_2_8_7_2 doi: 10.1021/ie060206u – ident: e_1_2_8_4_2 doi: 10.1007/978-3-642-55508-4 – volume: 22 start-page: 205 year: 1982 ident: e_1_2_8_22_2 article-title: Influence of molecular weight and molecular weight distribution on mechanical properties of polymers publication-title: J Polym Sci A: Polym Chem. contributor: fullname: Nunes RW – ident: e_1_2_8_23_2 doi: 10.1021/ie00073a018 – ident: e_1_2_8_6_2 doi: 10.1021/ie049534p – ident: e_1_2_8_18_2 doi: 10.1021/ma00040a021 – ident: e_1_2_8_2_2 doi: 10.1016/0009-2509(96)00024-3 – ident: e_1_2_8_13_2 – ident: e_1_2_8_10_2 |
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| Snippet | Traditionally, the methylmethacrylate (MMA) polymerization reaction process for plastic sheet production has been carried out using warming baths. However, it... Abstract Traditionally, the methylmethacrylate (MMA) polymerization reaction process for plastic sheet production has been carried out using warming baths.... |
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| SubjectTerms | Applications of mathematics to chemical engineering. Modeling. Simulation. Optimization Applied sciences Chemical engineering Chemical reactions dynamic optimization Exact sciences and technology Mathematical models Molecular weight Optimization Organic polymers PDE Physicochemistry of polymers PMMA Polymerization Preparation, kinetics, thermodynamics, mechanism and catalysts Reactors sheet reactor |
| Title | Dynamic optimization of the methylmethacrylate cell-cast process for plastic sheet production |
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