Integrated Dynamic Optimization and Scheduling of Polymerization Processes with First Principle Models

An integrated dynamic optimization strategy is presented for block copolymerization processes. First the reactor model, which has unstable modes and may lead to unbounded profiles under certain design and operating conditions, is derived. Second, optimal recipes for operating of the copolymerization process are determined. Finally, an optimization strategy for the integration of scheduling and dynamic process operation for general continuous/batch processes is considered. The resulting approach leads to significant improvements in productivity, while maintaining safe operation and satisfaction of product specifications. Differential‐algebraic optimization strategies based on simultaneous collocation and embedded within mixed integer nonlinear programming provides powerful strategies for the integration of recipe optimization with planning and scheduling. Significant process improvements are demonstrated on a semi‐batch polymerization process.