Skip to main content
Log in

Recent advances in polymer reaction engineering: Modeling and control of polymer properties

  • Review
  • Published:
Korean Journal of Chemical Engineering Aims and scope Submit manuscript

Abstract

Complex reaction kinetics and mechanisms, physical changes and transport effects, non-ideal mixing, and strong process nonlinearity characterize polymerization processes. Polymer reaction engineering is a discipline that deals with various problems concerning the fundamental nature of chemical and physical phenomena in polymerization processes. Mathematical modeling is a powerful tool for the development of process understanding and advanced reactor technology in the polymer industry. This review discusses recent developments in modeling techniques for the calculation of polymer properties including molecular weight distribution, copolymer composition distribution, sequence length distribution and long chain branching. The application of process models to the design of model-based reactor optimizations and controls is also discussed with some examples.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  • Anantawaraskul, S., Soares, J. B. P. and Wood-Adams, P.M., “Chemical Composition Distribution of Multicomponent Random Copolymers,” Paper presented at Polymer Reaction Engineering V, Quebec, Canada, May (2003).

  • Arzamendi, G. and Asua, J.M., “Modeling Gelation and Sol Molecular Weight Distribution in Emulsion Polymerization,”Macromolecules,28, 7479 (1995).

    Article  CAS  Google Scholar 

  • Bergström, C.H., Sperlich, B. R., RuotoistenmÄki, J. and SeppÄlÄ, J.V., “Investigation of the Microstructure of Metallocene-catalyzed Norbornene-ethylene Copolymers Using NMR Spectroscopy,”J. Polym. Sci.: Part A: Polym. Chem.,36, 1633 (1998).

    Article  Google Scholar 

  • Bon, S.A. F., Bosveld, M., Klumperman, B. and German, A. L., “Controlled Radical Polymerization in Emulsion,”Macromolecules,30, 324 (1997).

    Article  CAS  Google Scholar 

  • Bouzid, D. and McKenna, T. F., “Evolution of Particle Morphology During the Production of High Impact Polypropylene,” Paper presented at Polymer Reaction Engineering V, Quebec, Canada, May (2003).

  • de Brouwer, H., Tsavalas, J.G., Schork, F. J. and Monteiro, M. J., “Living Radical Polymerization in Miniemulsion Using Reversible Addition fragmentation Chain Transfer,”Macromolecules,33, 9239 (2000).

    Article  Google Scholar 

  • Butala, D.N., Fan, M.K.H. and Choi, K.Y., “Multiobjective Dynamic Optimization of Semibatch Free Radical Copolymerization Process with Interactive CAD Tools,”Comp. Chem. Eng., 12(11), 1115 (1988).

    Article  CAS  Google Scholar 

  • Butala, D. N., Liang, W. R. and Choi, K.Y., “Multiobjective Dynamic Optimization of Batch Free Radical Polymerization Process by Mixed Initiator Systems,”J. Appl. Polym. Sci.,44, 1759 (1992).

    Article  CAS  Google Scholar 

  • Butté, A., Ghielmi, A., Storti, G. and Morbidelli, M., “Calculation of Molecular Weight Distributions in Free-radical Polymerization with Chain Branching,”Macromol. Theory Simul.,8, 498 (1999a).

    Article  Google Scholar 

  • Butté, A., Storti, G. and Morbidelli, M., “Kinetics of Living Free Radical Polymerization,”Chem. Eng. Sci.,54, 3225 (1999b).

    Article  Google Scholar 

  • Butté, A., Storti, G. and Morbidelli, M., “Miniemulsion Living Free Radical Polymerization of Styrene,”Macromolecules,33, 3485 (2000).

    Article  Google Scholar 

  • Carrot, C. and Guillet, J., “From Dynamic Moduli to Molecular Weight Distribution: A Study of vArious Polydisperse Linear Polymers,”J. Rheol., 41(5), 1203 (1997).

    Article  CAS  Google Scholar 

  • Chatzidoukas, C., Perkins, J. D., Pistikopoulos, E.N. and Kiparissides, C., “Optimal Grade Transition and Selection of Closed-loop Controllers in a Gas-phase Olefin Polymerization Fluidized Bed Reactor,”Chem. Eng. Sci.,58, 3643 (2003).

    Article  CAS  Google Scholar 

  • Chen, C. C., “An Industry Perspective on Polymer Process Modeling,”CAST Communications, Summer (2002) [www.castdiv.org/summer02. htm].

  • Chien, D. C.H. and Penlidis, A., “On-line Sensors for Polymerization Reactors,”JMS-Rev. Macromol. Chem. Phys., C30(1), 1 (1990).

    CAS  Google Scholar 

  • Choi, K.Y., “Modeling of Polymerization Processes,” in Computer-Aided Design of Catalysts; Becker, E. R., Pereira, C. J., Eds., 335, Marcel Dekker, New York (1993).

    Google Scholar 

  • Choi, K.Y. and Ray, W.H., “The Dynamic Behavior of Fluidized Bed Reactors for Solid Catalyzed Gas Phase Olefin Polymerization,”Chem. Eng. Sci., 40(12), 2261 (1985).

    Article  CAS  Google Scholar 

  • Choi, K.Y. and Ray, W.H., “The Dynamic Behavior of Continuous Stirred Bed Reactors for the Solid Catalyzed Gas Phase Polymerization of Propylene,”Chem. Eng. Sci., 43(10), 2587 (1986).

    Article  Google Scholar 

  • Chum, S. and Oswald, T., “Using Polymer Structure/property Models to Accelerate the Development of Industrially Significant Applications for Polyolefins,” Paper presented at Polymer Reaction Engineering V, Quebec, Canada, May (2003).

  • Chum, P. S., Kao, C. I. and Knight, G.W., “Structure and Properties of Polyolefin Plastomers and Elastomers Produced from the Single Site, Constrained Geometry Catalyst,” Paper presented at Polyolefins IX, Houston, TX (1995).

  • Congalidis, J. P., Richards, J.R. and Ray, W.H., “Feedforward and Feedback Control of a Solution Copolymerization Reactor,”AIChE J.,35(6), 891 (1989).

    Article  CAS  Google Scholar 

  • Congalidis, J. P. and Richards, J. R., “Process Control of Polymerization Reactors: An Industrial Perspective,”Polym. React. Eng., 6(2), 71 (1998).

    CAS  Google Scholar 

  • Crowley, T. and Choi, K.Y., “Calculation of Molecular Weight Distribution from Molecular Weight Moments in Free Radical Polymerization,”Ind. Eng. Chem. Res.,36, 1419 (1997a).

    Article  CAS  Google Scholar 

  • Crowley, T. and Choi, K.Y., “Discrete Optimal Control of Molecular Weight Distribution in a Batch Free Radical Polymerization Process,”Ind. Eng. Chem. Res.,36, 3676 (1997b).

    Article  CAS  Google Scholar 

  • Crowley, T. and Choi, K.Y., “Control of Molecular Weight Distribution and Tensile Strength in a Free Radical Styrene Polymerization Process,”J. Appl. Polym. Sci.,70, 1017 (1998a).

    Article  CAS  Google Scholar 

  • Crowley, T. and Choi, K. Y., “Experimental Studies on Optimal Molecular Weight Distribution Control in a Batch Free Radical Polymerization Process,”Chem. Eng. Sci., 53(15), 2769 (1998b).

    Article  CAS  Google Scholar 

  • Crowley, T. and Choi, K.Y., “Copolymer Hydrodynamic Volume Distribution in a Free Radical Copolymerization Process,”Polym. React. Eng., 7(1), 43 (1999a).

    CAS  Google Scholar 

  • Crowley, T. J. and Choi, K.Y., “Control of Copolymer Hydrodynamic Volume Distribution in Free Radical Copolymerization Process,”Comp. Chem. Eng.,23, 1153 (1999b).

    Article  CAS  Google Scholar 

  • Cunningham, M. F., “Living/Controlled Radical Polymerizations in Dispersed Phase Systems,”Prog. Polym. Sci.,27, 1039 (2002).

    Article  CAS  Google Scholar 

  • Debling, J. A., Han, G. C., Kuijpers, J., VerBurg, J., Zacca, J. and Ray, W.H., “Dynamic Modeling of Product Grade Transitions for Olefin Polymerization Processes,”AIChE J.,40, 506 (1994).

    Article  CAS  Google Scholar 

  • Dotson, N.A., Galvan, R., Laurence, R. L. and Tirrell, M., “Polymerization Process Modeling,” VCH Publishers, New York (1996).

    Google Scholar 

  • Doyle III, F. J., Soroush, M. and Cordeiro, C., “Control of Product Quality in Polymerization Processes,”AIChE Symp. Ser.,98, 290 (2002).

    Google Scholar 

  • Dubé, M. A., Soares, B. P. O., Penlidis, A. and Hamielec, A. E., “Mathematical Modeling of Multicomponent Chain-growth Polymerizations in Batch, Semibatch, and Continuous Reactors: A Review,”Ind. Eng. Chem. Res.,36, 966 (1997).

    Article  Google Scholar 

  • Flores-Cerrillo, J. and MacGregor, J. F., “Within-batch and Batch-tobatch Inferential-adaptive Control of Semibatch Reactors: A Partial Least Square Approach,”Ind. Eng. Chem. Res.,42, 3334 (2003).

    Article  CAS  Google Scholar 

  • Floyd, S., Choi, K.Y., Taylor, T.W. and Ray, W.H., “Polymerization of Olefins Through Heterogeneous Catalysis. IV. Modeling of Heat and Mass Transfer Resistance in the Polymer Particle Boundary Layer,”J. Appl. Polym. Sci.,31, 2231 (1986).

    Article  CAS  Google Scholar 

  • Floyd, S., Heiskanen, T., Taylor, T.W. and Ray, W. H., “Polymerization of Olefins Through Heterogeneous Catalysis. VI. Effect of Particle Heat and Mass Transfer on Polymerization Behavior and Polymer Properties,”J. Appl. Polym. Sci.,33, 1021 (1987).

    Article  CAS  Google Scholar 

  • Georges, M. K., Veregin, R. P. N., Kazmaier, P.M. and Hamer, G.K., “Narrow Molecular Weight Resins by a Free-radical Polymerization Process,”Macromolecules,26, 2987 (1993).

    Article  CAS  Google Scholar 

  • Goldwasser, J. M., Rudin, A. and Elsdon, W. L., “Characterization of Copolymers and Polymer Mixtures by Gel Permeation Chromatography,”J. Liquid Chromatogr.,5, 2253 (1982).

    Article  CAS  Google Scholar 

  • Goldwasser, J.M. and Rudin, A., “Analysis of Block and Statistical Copolymers by Gel Permeation Chromatography: Estimation of Mark-Houwink Constants,”J. Liquid Chromatogr.,6, 2433 (1983).

    Article  CAS  Google Scholar 

  • Grof, Z., Kosek, J., Marek, M. and Adler, P. M., “Modeling of Morphogenesis of Polyolefin Particles: Catalyst Fragmentation,”AIChE J., 49(4), 1002 (2003).

    Article  CAS  Google Scholar 

  • Guan, Z., Chen, G. and Ma, S.X. S., “Control of Polymer Topology through Transition Metal Catalysis: Synthesis of Functional Olefin Copolymers Using a Chain Walking Catalyst,”Polymer Preprints, 44(2), 14 (2003).

    CAS  Google Scholar 

  • Han, C. D. and Kwack, T.H., “Rheology-processing-property Relationships in Tubular Blown Film Extrusion. I. High-pressure Lowdensity Polyethylene,”J. Appl. Polym. Sci.,28, 3399 (1983).

    Article  CAS  Google Scholar 

  • Han, C.D., Kim, Y. J., Chuang, H.K. and Kwack, T.H., “Rheological Properties of Branched Low-density Polyethylene,”J. Appl. Polym. Sci.,28, 3435 (1983b).

    Article  CAS  Google Scholar 

  • Hölderle, M., Baumert, M. and Mülhaupt, R., “Comparison of Controlled Radical Styrene Polymerizations in Bulk and Nonaqueous Dispersion,”Macromolecules,30, 3420 (1997).

    Article  Google Scholar 

  • Hutchinson, R.A. and Ray, W.H., “Polymerization of Olefins through Heterogeneous Catalysis. VII. Particle Ignition and Extinction Phenomena,”J. Appl. Polym. Sci.,34, 657 (1987).

    Article  CAS  Google Scholar 

  • Jeong, B.G., Yoo, K.Y. and Rhee, H. K., “Nonlinear Model Predictive Control Using a Wiener Model of a Continuous Methyl Methacrylate Polymerization Reactor,”Ind. Eng. Chem. Res., 40(25), 5968 (2001).

    Article  CAS  Google Scholar 

  • Keil, K., “The Use of High Throughput Screening Tools in Polymer Reaction Engineering,” Paper presented at Polymer Reaction Engineering V, Quebec, Canada, May (2003).

  • Kim, K. J. and Choi, K.Y., “On-line Estimation and Control of a Continuous Stirred Tank Polymerization Reactor,”J. Proc. Control.,1, 96 (1991).

    Article  Google Scholar 

  • Kim, K. J., Choi, K. Y. and Alexander, J. C., “Dynamics of a CSTR for Styrene Polymerization Initiated by a Binary Initiator System,”Polym. Eng. Sci.,30(5), 279 (1990).

    Article  CAS  Google Scholar 

  • Kim, K. J., Choi, K.Y. and Alexander, J. C., “Dynamics of a Cascade of Two Continuous Stirred Tank Polymerization Reactors with a Binary Initiator Mixture,”Polym. Eng. Sci.,31(5), 333 (1991).

    Article  CAS  Google Scholar 

  • Kim, K. J., Choi, K. Y. and Alexander, J. C., “Dynamics of a CSTR for Styrene Polymerization Initiated by a Binary Initiator Mixture. II. Effect of Viscosity Dependent Heat Transfer Coefficient,”Polym. Eng. Sci.,32(7), 494 (1992).

    Article  CAS  Google Scholar 

  • Kim, J. D., Soares, J. B. P. and Rempel, G. L., “Synthesis of Tailor-made Polyethylene through the Control of Polymerization Conditions Using Selectively Combined Metallocene Catalysts in a Supported System,”J. Polym. Sci.: Part A: Polym. Chem.,37, 331 (1999).

    Article  CAS  Google Scholar 

  • Kiparissdes, C., “Polymerization Reactor Modeling: A Review of Recent Developments and Future Directions,”Chem. Eng. Sci., 51(10), 1637 (1996).

    Article  Google Scholar 

  • Kittilsen, P., McKenna, T. and Svendsen, H., “The Interaction Between Mass Transfer Effects and Morphology in Heterogeneous Olefin Polymerization,” Paper presented at the first Eur. Conf. on React. Eng. of Polyolefins, Lyon, France, July (2000).

  • Kosek, J., Grof, Z., Salejova, G. and Marek, G., “Modeling of the Morphogenesis of Polyolefin Particles in Catalytic Reactors,” Paper presented at Polymer Reaction Engineering V, Quebec, Canada, May (2003).

  • Lavallée, C. and Berker, A., “More on the Prediction of Molecular weight Predictions of Linear Polymers from Their Rheology,”J. Rheol., 41(4), 851 (1997).

    Article  Google Scholar 

  • Matyjaszewski, K., Patten, T. E. and Xia, J., “Controlled/living Radical Polymerization. Kinetics of the Homogeneous Atom Transfer Radical Polymerization of Styrene,”J. Am. Chem. Soc.,119, 674 (1997).

    Article  CAS  Google Scholar 

  • McAuley, K. B. and MacGregor, J. F., “Optimal Grade Transition in a Gas Phase Polyethylene Reactor,”AIChE J.,38, 1564 (1992).

    Article  CAS  Google Scholar 

  • McKenna, T. F., Spitz, R., Kittilsen, P., Mattioli, V. and Martin, C., “Single Particle Transfer Phenomena: A Review and Future Directions,” ECOREP, Lyon, France, July (2000).

  • Ogunnaike, B.A., “The Role of CACSD in Contemporary Industrial Process Control,”IEEE Control Systems, April, 41 (1995).

  • Papavasiliou, G., Birol, I. and Teymour, F., “Calculation of Molecular weight Distributions in Non-linear Free-radical Polymerization Using the Numerical Fractionation Technique,”Macromol. Theory Simul.,11, 533 (2002).

    Article  CAS  Google Scholar 

  • Park, M. J. and Rhee, H.K., “Property Evaluation and Control in a Semibatch MMA/MA Solution Copolymerization Reactor,”Chem. Eng. Sci.,58, 603 (2003).

    Article  CAS  Google Scholar 

  • Park, S.Y., Choi, K.Y., Song, K.H. and Jeong, B.G., “Kinetic Modeling of Ethylene-norbornene Copolymerization Using Homogeneous Metallocene Catalysts,”Macromolecules,36, 4216 (2003).

    Article  CAS  Google Scholar 

  • Park, S.Y., “A Study on the Kinetics of Ethylene-norbornene Copolymerization over Homogeneous Metallocene Catalysts,” Ph.D. Thesis, University of Maryland, College Park (2003).

    Google Scholar 

  • Peterson, T., Hernandez, E., Arkun, Y. and Schork, F. J., “A Nonlinear DMC Algorithm and its Application to a Semibatch Polymerization Reactor,”Chem. Eng. Sci., 47(737)1992).

    Article  CAS  Google Scholar 

  • Pladis, P. and Kiparissides, C., “A Comprehensive Model for the Calculation of Molecular Weight-long-chain Branching Distribution in Free-radical Polymerizations,”Chem. Eng. Sci., 53(18), 3315 (1998).

    Article  CAS  Google Scholar 

  • Ray, W. H., “On the Mathematical Modeling of Polymerization Reactors,”J. Macromol. Sci. Rev. Macromolecular Chem. Phys.,C8, 1 (1972).

    Google Scholar 

  • Scali, C., Ciari, R., Bello, T. and Maschio, G., “Optimal Temperature for the Control of the Product Quality in Batch Polymerization: Simulation and Experimental Results,”J. Appl. Polym. Sci.,55, 945 (1995).

    Article  CAS  Google Scholar 

  • Schork, F. J., Desphande, P. B., Leffew, K.W., “Control of Polymerization Reactors,” Marcel Dekker, New York (1993).

    Google Scholar 

  • Seki, H., Ogawa, M., Ooyama, S., Akamatsu, K., Ohshima, M. and Yang, W., “Industrial Application of a Nonlinear Model Predictive Control to Polymerization Reactors,”Control Eng. Practice,9(8), 819 (2001).

    Article  Google Scholar 

  • Sirohi, A. and Choi, K. Y., “On-line Parameter Estimation in a Continuous Polymerization Process,”Ind. Eng. Chem. Res.,35, 1332 (1996).

    Article  CAS  Google Scholar 

  • Soares, J. B. P. and Hamielec, A. E., “Temperature Rising Elution Fractionation of Linear Polyolefins,”Polymer,36(8), 1639 (1995a).

    Article  CAS  Google Scholar 

  • Soares, J. B. P. and Hamielec, A. E., “Analyzing TREF Data by Stockmayer’s Bivariate Distribution,”Macromol. Theory Simul.,4, 305 (1995b).

    Article  CAS  Google Scholar 

  • Soares, J. B. P. and Hamielec, A. E., “Bivariate Chain Length and Long Chain Branching Distribution for Copolymerization of Olefins and Polyolefin Chains Containing Terminal Double Bonds,”Macromol. Theory Simul.,5, 547 (1996).

    Article  CAS  Google Scholar 

  • Soares, J. B. P. and Hamielec, A. E., “The Chemical Composition Component of the Distribution of Chain Length and Long Chain Branching for Copolymerization of Olefins and Polyolefin Chains Containing Terminal Double Bonds,”Macromol. Theory Simul.,6, 591 (1997a).

    Article  CAS  Google Scholar 

  • Soares, J. B. P., Kim, J. D. and Rempel, G., “Analysis and Control of the Molecular Weight and Chemical Composition Distributions of Polyolefins Made with Metallocene and Ziegler-Natta Catalysts,”Ind. Eng. Chem. Res.,36, 1144 (1997b).

    Article  CAS  Google Scholar 

  • Teymour, F. and Campbell, J.D., “Analysis of the Dynamics of Gelation in Polymerization Reactors Using the Numerical Fractionation Technique,”Macromolecules,27, 2460 (1994).

    Article  CAS  Google Scholar 

  • Teymour, F., “The Use of Digital Encoding for Modeling Copolymerization Systems,” Paper presented at Polymer Reaction Engineering V, Quebec, Canada (2003).

  • Tritto, I., Boggioni, L., Jansen, J., Thorshaug, K., Sacchi, M. C. and Ferro, D. R., “Ethylene-norbornene Copolymer Microstructure at Tetrad Level: Advances in Assignments of 13C NMR Spectra and Insights on Polymerization Mechanisms,” Paper presented at Int. Symp. on Polyolefins and Olefin Polymerization Catalysis, Tokyo, Japan, March 21–24 (2001).

  • Tritto, I., Boggioni, L., Jansen, J. C., Thorshaug, K., Sacchi, M. C. and Ferro, D. R., “Ethylene-norbornene Copolymers from Metallocenebased Catalysts: Microstructure at Tetrad Level and Reactivity Ratios,”Macromolecules,35, 616 (2002).

    Article  CAS  Google Scholar 

  • Tullo, A. H., “Single-site Success,”Chem. & Eng. News, 79(43), 35 (2001).

    Google Scholar 

  • Wang, Y., Seki, H., Ohyama, S., Akamatsu, K., Ogawa, M. and Ohshima, M., “Optimal Grade Transition Control for Polymerization Reactors,”Comp. & Chem. Eng.,24, 1555 (2000).

    Article  CAS  Google Scholar 

  • Weng, W., Market, E. J., Dekmezian, A.H. and Ruff, C. J., “Long Chain Branched Isotactic Polypropylene,”Macromolecules,35(10), 3838 (2002).

    Article  CAS  Google Scholar 

  • Weng, W., Hu, W. and Dekmezian, A. H., “Structure and Property of Long Chain Branched Isotactic Polypropylene,”Polymer Preprints, 44(2), 17 (2003).

    CAS  Google Scholar 

  • Wulkow, M., “The Simulation of Molecular Weight Distributions in Polyreaction Kinetics by Discrete Galerkin Methods,”Macromol. Theory Simul.,5, 393 (1996).

    Article  CAS  Google Scholar 

  • Wulkow, M., (Computer in Technology, http://www.cit-wulkow.de/), personal communication (2003).

  • Yiannoulakis, H., Yiagopoulos, A., Pladis, P. and Kiparissides, C., “Comprehensive Dynamic Model for the Calculation of the Molecular weight and Long Chain Branching Distributions in Metallocene-catalyzed Ethylene Polymerization Reactors,”Macromolecules,33, 2757 (2000).

    Article  CAS  Google Scholar 

  • Yoon, W. J., Ryu, J.H., Cheong, C. and Choi, K.Y., “Calculation of Molecular Weight Distribution in a Batch Thermal Polymerization of Styrene,”Macromol. Theory Simul.,7, 327 (1998).

    Article  CAS  Google Scholar 

  • Yoon, W. J., “Modeling of Industrial Styrene Polymerization Process,” unpublished work (2003).

  • Young, R. E., Bartusiak, R.D. and Fontaine, R.W., “Evolution of an Industrial Nonlinear Model Predictive Controller,”AIChE Symp. Ser.,98, 342 (2002).

    Google Scholar 

  • Zhang, M. and Ray, W.H., “Modeling of Living Free Radical Polymerization Processes. I. Batch, Semibatch, and Continuous Tank Reactors,”J. Appl. Polym. Sci.,86, 1630 (2002).

    Article  CAS  Google Scholar 

  • Zhu, S. and Li, D., “Molecular weight Distribution of Metallocene Polymerization with Long Chain Branching Using a Binary Catalyst System,”Macromol. Theory Simul.,6, 793 (1997).

    Article  CAS  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Kyu Yong Choi.

Additional information

This paper is dedicated to Professor Hyun-Ku Rhee on the occasion of his retirement from Seoul National University.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Yoon, W.J., Kim, Y.S., Kim, I.S. et al. Recent advances in polymer reaction engineering: Modeling and control of polymer properties. Korean J. Chem. Eng. 21, 147–167 (2004). https://doi.org/10.1007/BF02705393

Download citation

  • Received:

  • Accepted:

  • Issue Date:

  • DOI: https://doi.org/10.1007/BF02705393

Key words

Navigation