Tag Archives: Reaction Engineering

How To Overcome Process Scale-Up Challenges Using Process Analytical Technology (PAT)

Process Analytical Technology for Scale-up

Process Analytical Technology

During Part I of his two part The Role of Process Analytical Technology (PAT) in Green Chemistry and Green Engineering online seminar series, Dominique Hebrault discussed scale-up challenges faced today by chemists and engineers.  Too often, offline sampling methods – mostly chromatographic methods such as High Performance Liquid Chromatography (HPLC) or Gas Chromatography (GC) – are used to monitor processes which fail to resolve common issues like reaction monitoring, poor mass balance, delayed initiation/reaction stalled, and loss of yield/by-products.  From a reaction engineering standpoint, obtaining heat mass balance information and preliminary kinetic data can be difficult using traditional offline methods during process scale-up.  Forming the final solid can be challenging using traditional offline methods, including filtration/drying a bottleneck, excessive washing, polymorph inconsistency, and batch to batch variability can be difficult.
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Real-time monitoring of polymer growth kinetics using METTLER TOLEDO FBRM and PVM

polymer-growth-kinetics-FBRM-PVM-METTLER-TOLEDO
Wiley InterScience highlighted a paper that was just published in MacroMolecular Reaction Engineering by Professor Rolf Mülhaupt and his student Rainer Xalter of Albert-Ludwigs University in Freiburg, Germany.

This paper discusses the use of METTLER TOLEDO FBRM® and PVM® for real-time in-process monitoring of polymer and catalyst particles. During the polymerization of high-density polyethylene (HDPE), FBRM® and PVM® are used to determine polymer growth kinetics and to measure the effects of catalyst breakage and attrition within standard commercial-scale reactors.

“Unprecedented insight into the particle growth processes during ethylene slurry polymerizations catalyzed by supported single-site and Ziegler catalysts was gained by online monitoring using two different probes inserted directly into the reactor. FBRM online monitoring complemented by PVM online visualization of polymer particles allowed for the distinction of different types of particle growth processes depending on catalyst type and productivity.”

Citation: “On-line Monitoring of Polyolefin Particle Growth in Catalytic Olefin Slurry Polymerization by means of LasentecTM Focused Beam Reflectance Measurement (FBRM) and Video Microscopy (PVM) Probes”, R. Xalter and R. Mülhaupt, Macromol. React. Eng. 2010, 4, 25. http://doi.wiley.com/10.1002/mren.200900048?crel=US_AC_eAdv_Blog

 

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