Fast and reliable computational strategy for developing a rigorous model-driven soft sensor of dynamic molecular weight distribution

Key polymer properties are substantially directly related to the polymer molecular weight distribution (MWD). On-line monitoring and prediction of dynamic MWD profiles are highly important for on-line quality control of polymerization processes. In this study, a fast and reliable computational strategy for an equation-oriented model-based soft sensor for the high-density polyethylene grade transition process is developed. The simultaneous collocation approach is adopted to discretize the dynamic model. A novel moving finite element method is proposed to improve the on-line performance of the derived large-scale nonlinear equation systems. The sensitivity information of the nonlinear equation systems contributes to a convergence enhancement strategy for the sensor. The prediction accuracy and computational efficiency are demonstrated using industrial data. A potential application to extend the polymerization process with changeable flowsheet is also tested through simulation.