Automatic Continuous Online Monitoring of Polymerization Reactions


ACOMP is a smart manufacturing system that continuously analyzes polymers during production, yielding realtime data about reaction kinetics and polymer properties such as residual monomer, monomer conversion, polymer composition, molecular weight and intrinsic viscosity. This automated monitoring solution allows for tighter process control, resulting in increased polymer yields, quality and consistency, increased worker safety, reduced cycle times, reduced VOCs, and reduced energy and raw material usage. Beyond allowing the user to monitor polymerizations in real time, ACOMP enables the user an ability to control specific desired polymer characteristics.

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Benefits of ACOMP

Increased Polymer Yield, Quality and Consistency

Optimized Process Control

Reduced Cycle Times, VOCs and Material Usage

Anomaly Detection during Production

ACOMP Enables 17% Cycle Time Reduction

During the fracking boom there was high demand for a number of enhanced oil recovery chemicals, and many manufacturers sought ways to increase capacity with existing assets. In 2014 Nalco, an Ecolab Company, innovatively partnered with Fluence Analytics to pioneer the use of industrial ACOMP in one of its manufacturing facilities, subsequently leveraging the smart manufacturing system’s realtime data streams to reduce batch cycle times by 17%.

How ACOMP Works

Polymer is continuously extracted from the reactor

Automated real-time measurements are made with multiple sensors

Proprietary analysis algorithms output key parameters for optimization

This enables:

Optimized process control, Plant digitization, Reduced cycle times, Improved yields and consistency