<p> The work in this thesis focuses on the temperature control of a semi-batch polymerization reactor. The system is published by Chylla and Haase (1993) as an Industrial Challenge and is typical of reactors at S.C. Johnson Wax. The challenge is to find a single controller that can adequately regulate reactor temperature despite changing process conditions. The multi-product nature of the system makes it a particularly interesting problem. Several different controllers are implemented and evaluated in this thesis. The controllers are in part chosen to quantify the amount process information (large or small) required in a controller structure in order to achieve satisfactory control. Two of the most promising controllers are a PID with feedforward compensation and a Nonlinear Adaptive algorithm. It is found that in many cases, there may be little incentive to go to a complex model based controller as the simpler feedback algorithm provides adequate control. However, the nonlinear adaptive controller is more easily extended to multi-batch or multi-product situations because of its more general nature. The PID with feedforward compensation requires retuning for each new situation in order to maintain satisfactory control. </p> / Thesis / Master of Engineering (MEngr)

no / Batch and semi-batch reactors are widely used for fine chemical productions. The target in the fine chemical industry is to produce a high quality product and operational optimization is the key-element to match it. This work investigates how batch and semi-batch reactors can be optimized in order to increase the yield of a desired product. Optimization problem is formulated and applied to calculate the optimal operating parameters such as the reactor temperature and the feed flow rate. Comparison and considerations on the two reactor configurations are given.

Neste trabalho estudou-se o processo de coplimerização em emulsão de estireno e acrilato de butila em processo semicontínuo onde o produto final é um látice com alto teor de sólidos. Foi realizada uma série de experimentos de copolimerização em emulsão em um reator de vidro, empregando receitas com teores de sólidos na faixa de 50 a 64% em massa. Foram estudados os seguintes fatores: teor de sólidos, teor de ácido acrílico, teor de emulsificantes e tempo de adição dos monômeros. Os efeitos estudados são avaliados principalmente em termos de conversão, diâmetro médio das partículas, concentração de partículas, número médio de radicais por partícula, taxa de polimerização, viscosidade e fração de coágulos. Também se avaliou a distribuição de tamanhos de partículas para o processo. Utilizando informações experimentais e da literatura, foi aplicado um modelo matemático para o processo, com razoável adequação aos dados experimentais. / The aim of this work was the study of the high solid contents emulsion copolymerization of styrene and butyl acrylate in semi-batch process. Copolymerization reactions were undertaken in a glass reactor, and recipes with solid contents up to 64 wt.% were used. Were evaluated the effects of: solid contents on recipe, amounts of acrylic acid and surfactants on recipe and monomer feeding time. The effects were evaluated in terms of conversion, particle mean diameter, and particle concentration, average number of radicals per particle, polymerization rate, viscosity and coagulum content. It was performed a characterization of the particle size distribution for this process. Using experimental observations and literature information, it was applied a mathematical model for this process, with satisfactory agreement with experimental data.

Neste trabalho estudou-se o processo de coplimerização em emulsão de estireno e acrilato de butila em processo semicontínuo onde o produto final é um látice com alto teor de sólidos. Foi realizada uma série de experimentos de copolimerização em emulsão em um reator de vidro, empregando receitas com teores de sólidos na faixa de 50 a 64% em massa. Foram estudados os seguintes fatores: teor de sólidos, teor de ácido acrílico, teor de emulsificantes e tempo de adição dos monômeros. Os efeitos estudados são avaliados principalmente em termos de conversão, diâmetro médio das partículas, concentração de partículas, número médio de radicais por partícula, taxa de polimerização, viscosidade e fração de coágulos. Também se avaliou a distribuição de tamanhos de partículas para o processo. Utilizando informações experimentais e da literatura, foi aplicado um modelo matemático para o processo, com razoável adequação aos dados experimentais. / The aim of this work was the study of the high solid contents emulsion copolymerization of styrene and butyl acrylate in semi-batch process. Copolymerization reactions were undertaken in a glass reactor, and recipes with solid contents up to 64 wt.% were used. Were evaluated the effects of: solid contents on recipe, amounts of acrylic acid and surfactants on recipe and monomer feeding time. The effects were evaluated in terms of conversion, particle mean diameter, and particle concentration, average number of radicals per particle, polymerization rate, viscosity and coagulum content. It was performed a characterization of the particle size distribution for this process. Using experimental observations and literature information, it was applied a mathematical model for this process, with satisfactory agreement with experimental data.

No description available.

Yes / The formation of methyl decanoate (MeDC) by esterification reaction of decanoic acid with methanol through batch/continuous reactive distillation columns is operationally challenging, energy intensive and thus cost intensive operation due to complex thermodynamic behaviour of the reaction scheme. Aiming to overcome the equilibrium restriction of the decanoic acid (DeC) esterification operation, to improve the process efficiency and to reduce the total annualised cost (TAC), the semi-batch distillation column (SBD) and the recently proposed integrated semi-batch distillation column configuration (i-SBD) are investigated here. The performances of each of these column operations are evaluated in terms of minimum TAC for a given separation task. In both column configurations, additional operating constraints are considered into the optimization problem to prevent flooding of still pot due to the continuous charging of methanol into it. This study shows the superiority of i-SBD mode of operation over SBD operation in terms of TAC. Also, the optimization results for a defined separation task indicate that the performance of multi-interval control policy is overwhelmingly superior to the single-interval control operation in terms of operating batch time, and overall annual cost in the i-SBD system providing about a time saving of 82.75%, and cost (TAC) saving of 36.61% for a MeDC (product) concentration of 0.945 molefraction.

Yes / Batch reactive distillation is well known for improved conversion and separation of desired reaction products. However, for a number of reactions, the distillation can separate the reactants depending on their boiling points of them and thus not only reduces the benefit of the reactive distillation but also offers operational challenges for keeping the reactants together. Methyl lactate (ML) synthesis via the esterification of lactic acid (LA) with methanol in a reactive distillation falls into this category and perhaps that is why this process has not been explored in the past. The boiling points of the reactants (LA, methanol) are about 490 K and 337 K while those of the products (ML, water) are 417 K and 373 K respectively. Clearly in a conventional reactive distillation (batch or continuous) methanol will be separated from the LA and will reduce the conversion of LA to ML significantly. Here, first the limitations of the use of conventional batch distillation column (CBD) for the synthesis of ML is investigated in detail and a semi-batch reactive distillation (SBD) configuration is studied in detail where LA is the limiting reactant and methanol is continuously fed in excess in the reboiler allowing the reactants to be together for a longer period. However, this poses an operational challenge that the column has to be carefully controlled to avoid overflow of the reboiler at any time of the operation. In this work, the performance of SBD for the synthesis of ML is evaluated using model based optimization in which operational constraints are embedded. The results clearly demonstrate the viability of the system for the synthesis of ML.

Semi-batch crystallization experiments have been performedboth in a loop reactor and in stirred tank reactors.Hydrochloric acid was fed to a stirred solution of sodiumbenzoate, and benzoic acid immediately formed. Benzoic acid isformed in excess of the solubility making the solutionsupersaturated. The loop reactor is U-shaped. In one leg a propeller stirrerwas placed to circulate the solution and in the other a turbinestirrer was placed in front of the feed point to vary the localmixing intensity. The objective was to analyse the relativeimportance of different levels of mixing on the product sizedistribution. The importance of mixing as well as scaling-upeffects on the product size distribution were studied in threestirred tank reactors of volumes 2.5 L, 10 L, and 200 L. Thestirred tank reactors had different geometry and were equippedwith either a marine propeller or a pitched blade turbine. The weight mean size generally increases with increasingtotal feeding time and increasing mixing intensity. The weightmean size increases by locating an extra turbine impeller atthe feed point in the 10 L stirred tank reactor. The turbineimpeller provides the desired feed point mixing intensitywithout raising the mixing intensity of the whole tank. The weight mean size increases with decreasing feed pipediameter in the loop reactor and for low feed rates in the 10 Lstirred tank reactor. The weight mean size increasessignificantly by changing the feed pipe opening from circularto rectangular with a constant cross-sectional area at equalfeed rates. Backmixing is visually observed in the largest feedpipe diameter in the loop reactor, thus, reducing the weightmean size. However, backmixing is not considered to be adominant phenomenon in the present work. Mesomixing time constants have been calculated according tothe turbulent dispersion mechanism and the inertial-convectivemechanism. The time constants for mesomixing are generallylonger than the time constant for micromixing. Thus, the ratioof the mesomixing and the micromixing time constants shows aninfluence of mesomixing as is shown by the experimentalresults. The experimental results are best described by theinertial-convective disintegration mechanism showing that thefeed plume mixing increases with decreasing feed pipe diameterand increased feed point mixing. The weight mean size is not strongly affected by the reactorvolume. However, the mixing conditions in the reactors have astrong influence on the weight mean size. No suggestedscaling-up rule can satisfactorily predict the weight mean sizein the different volumes. No single physical parameter, such asthe local energy dissipation rate, the mean energy dissipationrate or the circulation time, can satisfactorily explain theexperimental results. A new dimensionless mixing parameter, TR,has been defined as the ratio of the total feeding time and themesomixing time constant. The mesomixing time constant isdefined as the shortest dimension of the feed pipe divided bythe resultant bulk velocity passing the feed pipe entrance. Theexperimental results from both the loop reactor and the stirredtank reactors of different volumes can be correlated with TR.The weight mean size increases with increasing TR. <b>Keywords</b>: reaction crystallization, precipitation,benzoic acid, macromixing, mesomixing, micromixing,semi-batch, loop reactor, backmixing, colour experiments,scaling-up. <b>Keywords</b>: reaction crystallization, precipitation,benzoic acid, macromixing, mesomixing, micromixing,semi-batch, loop reactor, backmixing, colour experiments,scaling-up.

<p>Semi-batch crystallization experiments have been performedboth in a loop reactor and in stirred tank reactors.Hydrochloric acid was fed to a stirred solution of sodiumbenzoate, and benzoic acid immediately formed. Benzoic acid isformed in excess of the solubility making the solutionsupersaturated.</p><p>The loop reactor is U-shaped. In one leg a propeller stirrerwas placed to circulate the solution and in the other a turbinestirrer was placed in front of the feed point to vary the localmixing intensity. The objective was to analyse the relativeimportance of different levels of mixing on the product sizedistribution. The importance of mixing as well as scaling-upeffects on the product size distribution were studied in threestirred tank reactors of volumes 2.5 L, 10 L, and 200 L. Thestirred tank reactors had different geometry and were equippedwith either a marine propeller or a pitched blade turbine.</p><p>The weight mean size generally increases with increasingtotal feeding time and increasing mixing intensity. The weightmean size increases by locating an extra turbine impeller atthe feed point in the 10 L stirred tank reactor. The turbineimpeller provides the desired feed point mixing intensitywithout raising the mixing intensity of the whole tank.</p><p>The weight mean size increases with decreasing feed pipediameter in the loop reactor and for low feed rates in the 10 Lstirred tank reactor. The weight mean size increasessignificantly by changing the feed pipe opening from circularto rectangular with a constant cross-sectional area at equalfeed rates. Backmixing is visually observed in the largest feedpipe diameter in the loop reactor, thus, reducing the weightmean size. However, backmixing is not considered to be adominant phenomenon in the present work.</p><p>Mesomixing time constants have been calculated according tothe turbulent dispersion mechanism and the inertial-convectivemechanism. The time constants for mesomixing are generallylonger than the time constant for micromixing. Thus, the ratioof the mesomixing and the micromixing time constants shows aninfluence of mesomixing as is shown by the experimentalresults. The experimental results are best described by theinertial-convective disintegration mechanism showing that thefeed plume mixing increases with decreasing feed pipe diameterand increased feed point mixing.</p><p>The weight mean size is not strongly affected by the reactorvolume. However, the mixing conditions in the reactors have astrong influence on the weight mean size. No suggestedscaling-up rule can satisfactorily predict the weight mean sizein the different volumes. No single physical parameter, such asthe local energy dissipation rate, the mean energy dissipationrate or the circulation time, can satisfactorily explain theexperimental results. A new dimensionless mixing parameter, TR,has been defined as the ratio of the total feeding time and themesomixing time constant. The mesomixing time constant isdefined as the shortest dimension of the feed pipe divided bythe resultant bulk velocity passing the feed pipe entrance. Theexperimental results from both the loop reactor and the stirredtank reactors of different volumes can be correlated with TR.The weight mean size increases with increasing TR.</p><p><b>Keywords</b>: reaction crystallization, precipitation,benzoic acid, macromixing, mesomixing, micromixing,semi-batch, loop reactor, backmixing, colour experiments,scaling-up.</p><p><b>Keywords</b>: reaction crystallization, precipitation,benzoic acid, macromixing, mesomixing, micromixing,semi-batch, loop reactor, backmixing, colour experiments,scaling-up.</p>

Batch distillation with chemical reaction when takes place in the same unit is referred to as batch reactive distillation process. The combination reduces the capital and operating costs considerably. Among many different types of batch reactive distillation column configurations, (a) conventional (b) inverted (c) semi-batch columns are considered here. Three reaction schemes such as (a) esterification of methanol (b) esterification of ethanol (c) hydrolysis of methyl lactate are studied here. Four different types of dynamic optimisation problems such as (a) maximum conversion (b) maximum productivity (c) maximum profit and (d) minimum time are formulated in this work. Optimal design and or operation policies are obtained for all the reaction schemes. A detailed rigorous dynamic model consisting of mass, energy balances, chemical reaction and thermodynamic properties is considered for the process. The model was incorporated within the dynamic optimisation problems. Control Vector Parameterisation (CVP) technique was used to convert the dynamic optimisation problem into a nonlinear programming problem which was solved using efficient SQP (Successive Quadratic Programming) method available within the gPROMS (general PROcess Modelling System) software. It is observed that multi-reflux ratio or linear reflux operation always led to better performance in terms of conversion, productivity for all reaction schemes compared to that obtained using single reflux operation. Feed dilution (in the case of ethanol esterification) led to more profit even though productivity was found to be lower. This was due to reduction in feed price because of feed dilution. Semi-batch reactive distillation opertation (for ethanol esterification) led to better conversion compared to conventional batch distillation, however, the total amount of acetic acid (reactant) was greater in semi-batch operation. Optimisation of design and operation (for ethanol esterification) clearly showed that a single cloumn will not lead to profitable operation for all possible product demand profile. Also change in feed and /or product price may lead to adjust the production target to maximise the profitability. In batch distillation, total reflux operation is recommended or observed at the begining of the operation (as is the case for methnaol or ethanol esterification). However, in the case of hydrolysis, total reflux operation was obseved at the end of the operation. This was due to lactic acid (being the heaviest) was withrawn as the final bottom product.