Polymerization Systems Engineering

Polymerization Systems Engineering – A Literature Review

L . T . Fan and J . S . Shastry

Institute for Systems Design and Optimization

and Department of Chemical Engineering.

Kansas State University. Manhattan, KS 66506

Taken from:

Journal of Polymer Science Macromolecular Reviews, Volume 7, Issue 1 (p 155-187)

INTRODUCTION

Man-made synthetic polymers are widely employed as substitutes for metal, wood, stone, glass, paper and a variety of macromolecular substances. These applications of polymer require specific properties such as toughness, flexibility, insulation, etc., which are related to the molecular weight, structure, molecular-weight distribution, and copolymer composition of the product polymer. These ultimate properties of the polymer are largely acquired in the reactor. The reactor must remove the heat of polymerization; provide necessary residence time; provide uniform mixing for good temperature control and reactor homogeneity; control the degree of backmixing in continuous polymerizations; and provide surface exposure (Schlegel [1972]). In addition, the reactor system must be amenable to control and be stable under normal operation. Polymerization systems engineering is a branch of systems engineering that deals with polymerization reactor systems ; this field of systems engineering encompasses analysis, modeling, dynamic and stability studies, design (or synthesis) and control of polymerization reactor systems. While many papers have been published on specific aspects of polymerization systems engineering, no comprehensive review on this subject is available. The purpose of this work is to review in general the research in the area of polymerization systems engineering and, in particular, the research on analysis, selection, design, control and optimization of polymerization reactors.

It is hoped that this review will serve as a supplement to the two related reviews published recently. ‘The one by Lenz [1970] reviewed the works on “applied polymerization reaction kinetics” and is generally concerned with the study of the “chemistry” of polymerization reactions and their rates. It also included work related to different initiation systems and different methods of polymerization. In contrast, Seymour [1970] reviewed some recent developments in plastics science and technology and in treating and characterizing the final polymer product. The latest developments in synthetic elastomer technology, cellular plastics, synthetic fibers, polymer coatings, and several other topics were also included. The present review covers the area of polymer science and technology not included in these two reviews. To produce polymer products, considerable effort is required “after” the rate constants have been determined and “before” the polymer is molded; it includes analysis, design, construction, operation, control and optimization of reactor systems for production of polymers. The review is divided into six sections. In the first section, basic concepts related to polymerization reactions are presented; the other sections are devoted to various aspects of polymerization systems engineering such as thermodynamics, modeling and simulation, optimal design, dynamic optimization, stability analysis and optimal systems synthesis