INSUS models the relationship between polymerization conditions and product properties from your own reactor and lab history, then works backwards from the molecular weight and polydispersity you need to candidate conditions that could reach them. Process teams keep the decision.
01
Target-first: the property comes before the parameter.
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Trade-offs with reaction time are shown, not hidden.
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Calibrated to one catalyst system and process at a time.
The problem
Molecular weight, polydispersity and reaction time are influenced by polymerization parameters that act together: monomer-to-catalyst ratio, co-catalyst ratio, temperature and time. When a specification changes, process teams often adjust one variable at a time across successive batches. Each trial costs reactor time and material, and a target outside recent history usually means another process-development round rather than a search through what the plant already knows.
The shift
Process and formulation teams stay responsible for every operating condition. What changes is whether candidate parameters associated with the required molecular weight and PDI are visible before another trial batch is committed.
Today
With INSUS
How it works
This fits OptiStudio as process and quality decision support beside existing polymer synthesis workflows. Access is read-only. It does not write setpoints to the reactor control system.
Connect
Connect reactor process parameters such as monomer-to-catalyst ratio, co-catalyst ratio, reaction temperature and time with the molecular weight and PDI results they produced, plus catalyst system information from existing DCS/SCADA, historian and laboratory QC systems.
Understand
Analyze historical batches to establish how parameters have influenced molecular weight and polydispersity for this reactor and this catalyst and co-catalyst system.
Predict
For candidate conditions, estimate the expected molecular weight, PDI and reaction time before the process team commits reactor time to them.
Advise
Identify candidate parameter combinations for the desired molecular weight and PDI, presenting trade-offs against reaction time so the team can choose the operating compromise.
Verify
Compare predicted molecular weight and PDI with laboratory results from the batches that are run, and feed new results back so calibration improves against this plant's own process.
Getting started
For specialty polymer operations that already collect reactor parameters and laboratory property results. Delivered through OptiStudio as polymerization decision support. Expert Services can help with data assessment and validation. Advisory and read-only. No new reactor hardware.
Related for specialty chemicals
Polymerization target-property optimization sits beside thermal runaway risk prediction and SVHC Article 33 compliance tracking on the same specialty chemicals operation.
Hitting a new molecular weight and PDI target often means iterative trial batches. This use case predicts property outcomes and recommends candidate process conditions for process-team review.
Historical reactor process parameters with matching laboratory molecular weight and PDI measurements, plus catalyst and co-catalyst information. No new sensors when those records already exist.
No. It provides candidate conditions for process and formulation teams to evaluate. Nothing is written to the reactor control system.
Parameters such as monomer-to-catalyst ratio, co-catalyst-to-catalyst ratio, reaction temperature and reaction time, subject to available data and process constraints.
Yes, where sufficient process and QC data exists. A relationship learned for one catalyst system should not be assumed to apply to another.
Through OptiStudio as process and quality decision support. Expert Services can support data assessment, integration and validation with your polymer process team.
Performance depends on reliable process and laboratory history. Recommendations are reactor-, catalyst- and chemistry-specific. Published multi-objective polymerization studies are not INSUS results for your plant.
Specialty chemicals · Polymer synthesis
Start with one catalyst system and the batch history behind it. The useful first answer is how well your own records already predict the properties they produced.
