In the last years important efforts have been made to convert the traditional batch polymer production to continuous. This transition allows to overcome most of the limitations of discontinuous or semi-continuous processes, such as environmental and safety issues and inadequate product quality. In this work we propose a model–based strategy to convert the solution free-radical polymerization of non-ionized methacrylic acid (MAA) from semibatch to continuous while preserving the product average molecular weight and polymer content. First, a purely kinetic model for the polymerization of MAA was validated for batch, semibatch and continuous stirred tank reactors (CSTR). Then, a basic optimization approach was applied to guide the transition of a selected semibatch process to a CSTR. This strategy results in a substantial productivity increase (5.1 times higher than in the original semibatch) while preserving the selected polymer average molecular weight and dry content. Finally, in order to reduce the residual monomer in the product leaving the CSTR, we simulated the addition of a tubular reactor. This was modelled introducing a small plug flow reactor in series to the CSTR. This approach represents an effective and robust tool for polymer manufacturers to assist switching their productions to continuous preserving their product portfolio.

在过去的几年中，为将传统的间歇式聚合物生产转换为连续生产做出了重要努力。这种过渡可以克服不连续或半连续过程的大多数局限性，例如环境和安全问题以及产品质量不足。在这项工作中，我们提出了一种基于模型的策略，以将非离子化甲基丙烯酸（MAA）的溶液自由基聚合从半间歇转化为连续，同时保留产物的平均分子量和聚合物含量。首先，针对间歇，半间歇和连续搅拌釜反应器（CSTR）验证了MAA聚合的纯动力学模型。然后，应用了一种基本的优化方法来指导所选的半批量过程向CSTR的过渡。该策略可大幅提高生产率（5。比原始半批产品高1倍），同时保留所选聚合物的平均分子量和干含量。最后，为了减少离开CSTR的产物中的残留单体，我们模拟了管状反应器的添加。以此为模型，在CSTR中引入了一个串联的小型活塞流反应器。这种方法为聚合物制造商提供了一种有效而强大的工具，可帮助他们将生产转换为持续保留其产品组合。