Process for the production of polymers

Abstract

A process for preparing a polymer may be monitored, controlled, or monitored and controlled using the turbidity of a process stream. The process stream is a dispersed phase fluid including polymer particles. The interaction of the process stream and light passing through the senor probe is measured and used to define a value for the turbidity of the process stream. The value for the turbidity of the process stream is a component of an algorithm used to determine in real time the polymer particle size or the concentration of polymer particles in the process stream and is used to monitor, control, or monitor and control the process for preparing a polymer. Polystyrene and Polyethylene are among the polymers that may be prepared using this process.

1 . A process for preparing a polymer comprising preparing a polymer using a process comprising at least one process stream, the at least one process stream comprising a dispersed phase fluid comprising polymer particles, and the process further comprising contacting at least a portion of the at least one process stream with a sensor probe connected to a turbidity meter and passing light from a light source through the sensor probe and into the turbidity meter; wherein the interaction of the process stream and the light passing through the senor probe is measured and used to define a value for the turbidity of the at least one process stream; and wherein the value for the turbidity of the at least one process stream is a component of an algorithm used to determine in real time the polymer particle size or the concentration of polymer particles in the at least one process stream to monitor, control, or monitor and control the process for preparing a polymer.  
     
     
         2 . The process of  claim 1  wherein the polymer is polystyrene, polypropylene or polyethylene.  
     
     
         3 . The process of  claim 1  wherein the polymer is a copolymer of polystyrene, a copolymer of polypropylene or a copolymer of polyethylene.  
     
     
         4 . The process of  claim 1  wherein the light source, turbidity meter and sensor probe are connected by a fiber optic cable  
     
     
         5 . The process of  claim 1  wherein the turbidity meter and the light source are separate.  
     
     
         6 . The process of  claim 1  wherein the turbidity meter and the light source are an integrated unit.  
     
     
         7 . The process of  claim 1  wherein the sensor probe is selected from the group consisting of transmittance probes, reflectance probes, and attenuated reflectance probes  
     
     
         8 . The process of  claim 1  wherein the probe is in close proximity to the turbidity meter.  
     
     
         9 . The process of  claim 1  wherein the probe is remote from the turbidity meter.  
     
     
         10 . The process of  claim 1  additionally comprising interfacing the turbidity meter to a process controller.  
     
     
         11 . The process of  claim 10  wherein the process controller is a PID controller.  
     
     
         12 . The process of  claim 10  wherein the process controller is an artificial intelligence based controller.  
     
     
         13 . The process of  claim 12  wherein the artificial intelligence based controller is a neural net artificial intelligence controller.  
     
     
         14 . The process of  claim 1  wherein there are two probes connected to the turbidity meter.  
     
     
         15 . The process of  claim 14  wherein both probes are in the same process stream.  
     
     
         16 . The process of  claim 14  wherein the probes are in separate process streams.  
     
     
         17 . The process of  claim 1  wherein the turbidity meter is automated  
     
     
         18 . The process of  claim 1  wherein the turbidity meter incorporates a computer to perform some or all of the processes of determining turbidity and making calculations therewith.  
     
     
         19 . A process for preparing a polystyrene polymer comprising preparing a polystyrene polymer using a process comprising at least one process stream, the at least one process stream comprising a dispersed phase fluid comprising polystyrene polymer particles, and the process further comprising contacting at least a portion of the at least one process stream with a sensor probe connected to a turbidity meter and passing light from a light source through the sensor probe and into the turbidity meter; wherein the interaction of the process stream and the light passing through the senor probe is measured and used to define a value for the turbidity of the at least one process stream; and wherein the value for the turbidity of the at least one process stream is a component of an algorithm used to determine in real time the polystyrene polymer particle size or the concentration of polystyrene polymer particles in the at least one process stream to monitor, control, or monitor and control the process for preparing a polystyrene polymer.  
     
     
         20 . The process of  claim 19  wherein the light source, turbidity meter and sensor probe are connected by a fiber optic cable.  
     
     
         21 . A process for preparing a polyethylene polymer comprising preparing a polyethylene polymer using a process comprising at least one process stream, the at least one process stream comprising a dispersed phase fluid comprising polyethylene polymer particles, and the process further comprising contacting at least a portion of the at least one process stream with a sensor probe connected to a turbidity meter and passing light from a light source through the sensor probe and into the turbidity meter; and wherein the interaction of the process stream and the light passing through the senor probe is measured and used to define a value for the turbidity of the at least one process stream; wherein the value for the turbidity of the at least one process stream is a component of an algorithm used to determine in real time the polyethylene polymer particle size or the concentration of polyethylene polymer particles in the at least one process stream to monitor, control, or monitor and control the process for preparing a polyethylene polymer.  
     
     
         22 . The process of  claim 19  wherein the light source, turbidity meter and sensor probe are connected by a fiber optic cable.