聚丁二烯批次製程之動態建模以及溫度控制

Abstract

聚丁二烯乳膠 (PBL) 是丙烯腈-丁二烯-苯乙烯共聚物 (ABS) 的共聚合過程中至關重要的組成部分，ABS 是一種廣泛使用的工業聚合物。然而，PBL 乳化聚合存在一些挑戰。除了本身反應的高放熱與單一操作批次間之黏度上升所造成的熱交換器熱傳效率降低之外，隨著操作批次次數的增加，熱交換器上所累積之聚合物結垢。這些因素都會導致潛在的溫度控制高超越比，進而導致不同批次之間的最終產品質量不一致。 為了解決這些問題，工程師通常會訴諸於人工調整控制器参数與製程變數。然而，這種方法由於操作人員經驗的差異而缺乏一致性，導致生產力和產品質量不可預測。 本研究針對於聚丁二烯乳化聚合批次製程相關的挑戰進行探討。通過開發能夠捕捉實際工廠動態的數學模型，進而優化製程生產力與控制策略並保持不同批次之間的一致產品質量。

Polybutadiene Latex (PBL) is a crucial component in the copolymerization process for Acrylonitrile Butadiene Styrene (ABS), a widely used industrial polymer. However, the control of PBL emulsion polymerization reactors are particularly difficult due to the multiphase nature of emulsion systems and the complicated nonlinear process dynamics[39]. To address these issues, engineers often resort to manual adjustments of process parameters. However, this approach suffers from inconsistencies due to variations in individual operating experience, leading to unpredictable productivity and product quality. This research addresses the challenges associated with polybutadiene emulsion polymerization, including exothermic reactions, increasing viscosity within each batch operation, and polymeric fouling accumulates on heat exchangers across batches. These factors contribute to potential temperature control overshoots, resulting in inconsistent final product quality across different batches. By developing a mathematical model that captures real-plant dynamics, the research seeks to optimize productivity, control strategy and maintain consistent product quality across batches.