Process design of batch reactors using multi-objective optimization for synthesis of butylated urea formaldehyde resins

Abstract Butylated urea formaldehyde resins are amino resins that are key intermediates for manufacturing water-resistant paints and coating materials. Owing to the complex kinetics involved in their synthesis, it has been a challenge to establish design criteria for optimum reactor operations. For instance, for better water-resistant properties and for synthesizing specialty nanocomposites, from BUF, maximum butylation and maximum X-condensates (-CH2-O-CH2- linkages) are respectively required, along with minimum free formaldehyde. We, therefore, harness multi-objective optimization approach to establish optimal trade-offs among various mutually conflicting objectives. In particular, we establish process design criteria by performing 2 and 3 objective optimizations and demonstrate that the latter, provides wider range of choices and better trade-offs for reactor operation compared to the former. Further, we also calculate optimal temperature trajectories and reaction times to achieve these objectives. Our findings can be utilized to determine operating conditions for optimizing resin quality of particular specifications.