A Semi-batch Polymerization Process for Fault Simulation

A semi-batch polymerization process Simulink model for thermal runaway fault simulation

This is a Simulink model of a semi-batch polymerization process, where the process is represented by 15 ODEs (ordinary differential equations) which are mass and energy balances around the system.

A semi-batch polymerization process is simulated inclusing preparation stage, production stage, and final stage. In reaction stage, Pressure control maintains a constant reactor gas pressure by adjusting the monomer feed flow. Temperature control ensures a constant reactor temperature by adjusting the jacket cooling water inlet flow. Reaction rate control maintains a stable reaction rate by adjusting the initiator feed flow. The overall objective of this process is to ensure that the polymerization reaction proceeds at an appropriate rate while maintaining stable temperature and pressure.

Thermal runaway faults can be simulated for process monitoring research purposes. Thermal runaway faults include excessive initiator addition, the Gel effect, heat transfer fouling, inaccuracies in thermometer readings, and sticking of the jacket cooling water valve. When no faults are simulated, one can gain process understanding of the system dynamics under normal operation.