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.

Dynamic modelling and optimization of three different processes namely (a) bulk polymerization of styrene, (b) solution polymerization of methyl methacrylate (MMA) and (c) emulsion copolymerization of Styrene and MMA in batch and semi-batch reactors are the focus of this work. In this work, models are presented as sets of differential-algebraic equations describing the process. Different optimization problems such as (a) maximum conversion (Xn), (b) maximum number average molecular weight (Mn) and (c) minimum time to achieve the desired polymer molecular properties (defined as pre-specified values of monomer conversion and number average molecular weight) are formulated. Reactor temperature, jacket temperature, initial initiator concentration, monomer feed rate, initiator feed rate and surfactant feed rate are used as optimization variables in the optimization formulations. The dynamic optimization problems were converted into nonlinear programming problem using the CVP techniques which were solved using efficient SQP (Successive Quadratic Programming) method available within the gPROMS (general PROcess Modelling System) software. The process model used for bulk polystyrene polymerization in batch reactors, using 2, 2 azobisisobutyronitrile catalyst (AIBN) as initiator was improved by including the gel and glass effects. The results obtained from this work when compared with the previous study by other researcher which disregarded the gel and glass effect in their study which show that the batch time operation are significantly reduced while the amount of the initial initiator concentration required increases. Also, the termination rate constant decreases as the concentration of the mixture increases, resulting rapid monomer conversion. The process model used for solution polymerization of methyl methacrylate (MMA) in batch reactors, using AIBN as the initiator and Toluene as the solvent was improved by including the free volume theory to calculate the initiator efficiency, f. The effects of different f was examined and compared with previous work which used a constant value of f 0.53. The results of these studies show that initiator efficiency, f is not constant but decreases with the increase of monomer conversion along the process. The determination of optimal control trajectories for emulsion copolymerization of Styrene and MMA with the objective of maximizing the number average molecular weight (Mn) and overall conversion (Xn) were carried out in batch and semi-batch reactors. The initiator used in this work is Persulfate K2S2O8 and the surfactant is Sodium Dodecyl Sulfate (SDS). Reduction of the pre-batch time increases the Mn but decreases the conversion (Xn). The sooner the addition of monomer into the reactor, the earlier the growth of the polymer chain leading to higher Mn. Besides that, Mn also can be increased by decreasing the initial initiator concentration (Ci0). Less oligomeric radicals will be produced with low Ci0, leading to reduced polymerization loci thus lowering the overall conversion. On the other hand, increases of reaction temperature (Tr) will decrease the Mn since transfer coefficient is increased at higher Tr leading to increase of the monomeric radicals resulting in an increase in termination reaction.

Dynamic modelling and optimization of three different processes namely (a) bulk polymerization of styrene, (b) solution polymerization of methyl methacrylate (MMA) and (c) emulsion copolymerization of Styrene and MMA in batch and semi-batch reactors are the focus of this work. In this work, models are presented as sets of differential-algebraic equations describing the process. Different optimization problems such as (a) maximum conversion (Xn), (b) maximum number average molecular weight (Mn) and (c) minimum time to achieve the desired polymer molecular properties (defined as pre-specified values of monomer conversion and number average molecular weight) are formulated. Reactor temperature, jacket temperature, initial initiator concentration, monomer feed rate, initiator feed rate and surfactant feed rate are used as optimization variables in the optimization formulations. The dynamic optimization problems were converted into nonlinear programming problem using the CVP techniques which were solved using efficient SQP (Successive Quadratic Programming) method available within the gPROMS (general PROcess Modelling System) software. The process model used for bulk polystyrene polymerization in batch reactors, using 2, 2 azobisisobutyronitrile catalyst (AIBN) as initiator was improved by including the gel and glass effects. The results obtained from this work when compared with the previous study by other researcher which disregarded the gel and glass effect in their study which show that the batch time operation are significantly reduced while the amount of the initial initiator concentration required increases. Also, the termination rate constant decreases as the concentration of the mixture increases, resulting rapid monomer conversion. The process model used for solution polymerization of methyl methacrylate (MMA) in batch reactors, using AIBN as the initiator and Toluene as the solvent was improved by including the free volume theory to calculate the initiator efficiency, f. The effects of different f was examined and compared with previous work which used a constant value of f 0.53. The results of these studies show that initiator efficiency, f is not constant but decreases with the increase of monomer conversion along the process. The determination of optimal control trajectories for emulsion copolymerization of Styrene and MMA with the objective of maximizing the number average molecular weight (Mn) and overall conversion (Xn) were carried out in batch and semi-batch reactors. The initiator used in this work is Persulfate K2S2O8 and the surfactant is Sodium Dodecyl Sulfate (SDS). Reduction of the pre-batch time increases the Mn but decreases the conversion (Xn). The sooner the addition of monomer into the reactor, the earlier the growth of the polymer chain leading to higher Mn. Besides that, Mn also can be increased by decreasing the initial initiator concentration (Ci0). Less oligomeric radicals will be produced with low Ci0, leading to reduced polymerization loci thus lowering the overall conversion. On the other hand, increases of reaction temperature (Tr) will decrease the Mn since transfer coefficient is increased at higher Tr leading to increase of the monomeric radicals resulting in an increase in termination reaction.

The polymerization of methyl methacrylate (MMA) was investigated in this dissertation. Selected kinetic models from the literature were reviewed, and two new, generalized models of diffusion-limited effects (gel- and glass effects), derived from the current models were proposed and tested for bulk and solution polymerization of MMA in batch and semi-batch reactors, under isothermal and non-isothermal conditions. The newly proposed models include the capability of modeling termination by combination, radical transfer to monomer and depropagation reaction. The new and previous models were compared with experimental data of bulk and solution polymerizations of MMA, under a selection of non-steady state processes conditions (initiator and monomer feed, step changes in temperature) and compositions (initiator and chain transfer agents, regarding both type and dosages). The particular case of a non-isothermal bulk polymerization was also investigated. A simulation program (Reactormodel) was developed in Matlab, and its algorithm is provided. / Sem resumo.