Dynamic optimization of a two-stage emulsion polymerization to obtain desired particle morphologies

Particle morphology is a key property of hybrid waterborne polymer dispersions that are used in high-end applications. However, evolving these product-by-process material properties is still mainly achieved by trial-and-error guided semi-empirical knowledge. In this work, a recently published mathematical model for the development of the particle morphology and a dynamic optimization method based on the direct single shooting approach are used to demonstrate in silico the feasibility of process optimization aimed at controlling particle morphology of waterborne polymer dispersions. This knowledge-based approach is assessed for existing and new materials with distinct particle morphologies. The batch times can be reduced by up to 13%.