Nitrile Rubber Reactor Operation Troubleshooting with Principal Component Analysis

Principal Component Analysis (PCA) is employed as a tool in order to demonstrate yet another application of the technique, and, most importantly, to show that results from the statistical multivariate technique do make physico-chemical sense. The operation of a typical emulsion copolymerization of acrylonitrile and butadiene (nitrile butadiene rubber, NBR) is used as an example of process troubleshooting. In more general terms, a statistical tool is used to aid process data analysis and process operation (recipe, product property) troubleshooting.

The goal is to produce consistent Mooney Viscosity (MV) among different batches. The observation is that varying induction times lead to Mooney Viscosity inconsistencies. Firstly, we show results from the application of PCA to process data. Secondly, we deal with an even more important (and often ignored) question by examining whether the trends indicated by PCA make process sense.