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Interactively connecting our polymer production design

Project description

Bridging the gap between polymer chemistry and manufacturing

Innovation in the design of high-quality, efficient and recyclable polymers is hindered by issues of energy consumption, product heterogeneity and poor integration between synthesis and processing. Today, polymer reaction engineering and polymer processing operate largely in isolation, limiting performance optimisation. Funded by the ERC, the POLY-DESIGN project will address this gap with a next-generation multiscale modelling tool. By tracking molecular and morphological changes across all length scales, the tool predicts aspects of polymer behaviour from chemical synthesis to final shaping. It applies to linear, branched, crosslinked and blended polymers. Overall, POLY-DESIGN aims to deliver sustainable, cost-effective and higher-quality polymers. This will transform commodity and high-tech polymer manufacturing.

Objective

A challenge in the polymer industry is the design of molecular and morphological properties along the whole production chain, minimizing energy consumption and product heterogeneity, and ensuring recyclability. Ideally, we need to track the compositional/topological variations and interactions of individual species during (i) synthesis, hence, the polymer reaction engineering (PRE) stage; and (ii) downstream final material shaping, hence, the polymer processing (PP) stage (e.g. (reactive) extrusion).

Today, the connection between the PRE and PP stage is weak and monodirectional, with only average, not distributed, ballpark PRE characteristics inputted in PP optimization. Both stages although share common bottlenecks such as micro-scale viscosity changes, meso-scale mixing limitations, and macro-scale concentration/temperature gradients.

POLY-DESIGN aims at next-generation polymer performance intensification and functionality design by a generic PRE-PP multi-scale modelling tool, tracking all changes at all length scales during synthesis and processing. This ambitious approach interactively connecting PRE and PP can tackle complex demanding products, and cost efficiently produced goods that will drive the commodity and high-tech polymer market.

A validated PRE multi-scale modelling tool is applied to access all distributed PRE characteristics, uniquely for (i) linear and branched/crosslinked (co)polymers; (i) lab and commercial polymers; and (iii) pure polymers and their blends. The polymer (blend) viscoelasticity is calculated with a multi-scale PP modelling tool at any PP shear rate and temperature for any set of PRE characteristics. In this way, an industrial PP unit can be designed from the chemical to the material level and reversely thanks to a flexible PRE-PP connection.

Demonstrator cases are included for more sustainable and higher quality manufacturing of virgin and recycled polymers, benefiting from design in the PRE or PP stage, or both.

Fields of science (EuroSciVoc)

Keywords

Programme(s)

Topic(s)

Funding Scheme

HORIZON-ERC - HORIZON ERC Grants

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Call for proposal

(opens in new window) ERC-2024-ADG

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Host institution

UNIVERSITEIT GENT
Net EU contribution
€ 2 496 000,00
Address
SINT PIETERSNIEUWSTRAAT 25
9000 Gent
Belgium
Region
Vlaams Gewest Prov. Oost-Vlaanderen Arr. Gent
Activity type
Higher or Secondary Education Establishments
Links
Total cost
No data

Beneficiaries (1)