Product Quality Control in Semi-Batch Reactors using Mid-Course Correction Policies

A practical approach to the control of final product quality in semi-batch reactors is proposed. It is based on the use of readily available on-line measurements such as temperatures plus a few off-line analyses obtained from one or more samples taken from the reactor throughout the course of the batch run. These measurements are used with either a theoretically-based model or with simple empirical regression models to predict the final product properties. If the predictions fall outside of a defined no-control region, then a mid-course correction is made to bring the product quality closer to target. The approach is illustrated for the control of molecular weight and cross-link density in the simulated semi-batch emulsion polymerization ofstyrene-butadiene rubber (SBR).