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Dynamic On-line Re-optimization Control of A Batch MMA Polymerization Reactor Using Hybrid Neural Network Models

A hybrid neural network model based on-line re-optimization control strategy is developed for a batch polymerization reactor. To address the difficulties in batch polymerization reactor modeling, the hybrid neural network model contains a simplified mechanistic model covering material balance assuming perfect temperature control, and recurrent neural networks modeling the residuals of the simplified mechanistic model due to imperfect temperature control. This hybrid neural network model is used to calculate the optimal control policy. A difficulty in the optimal control of batch polymerization reactors is that the optimization effort can be seriously hampered by unknown disturbances such as reactive impurities and reactor fouling. With the presence of an unknown amount of reactive impurities, the off-line calculated optimal control profile will be no longer optimal. To address this issue, a strategy combining on-line reactive impurity estimation and on-line reoptimization is proposed in this paper. The amount of reactive impurities is estimated on-line during the early stage of a batch using a neural network based inverse model. Based on the estimated amount of reactive impurities, on-line re-optimization is then applied to calculate the optimal reactor temperature profile for the remaining time period of the batch reactor operation. This approach is illustrated on the optimization control of a simulated batch methyl methacrylate polymerization process.