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Polymer Reaction Engineering, Vol.5, No.3, 85-124, 1997
Dynamic modeling of continuous miniemulsion polymerization reactors
The dynamic model developed in this work uses a particle number (PN) approach to simulate conventional emulsion (also called macroemulsion) and miniemulsion polymerizations for a plug-flow reactor and a continuous stirred tank reactor (PFR-CSTR) in series. A major objective of this work is to observe and analyze the differences between macro and miniemulsion polymerization as a result of the different nucleation mechanisms (micellar or droplet, respectively). In addition, a simplified steady state CSTR model is developed to provide additional insight into the effects of droplet nucleation in continuous reactors. It is demonstrated that the rate of a miniemulsion polymerization in a CSTR is a function of the residence time, the initiator concentration and the initial droplet size. In most cases the rate of polymerization using a miniemulsion recipe is greater than that for a conventional emulsion recipe at the same operating conditions. Since particle nucleation and growth are coupled for macroemulsion polymerization in a CSTR, the number of particles generated in a CSTR is only a fraction of the number of particles generated in a batch reactor. Therefore, a PFR upstream of the CSTR has a dramatic effect on the rate of polymerization in the CSTR. However, since miniemulsions are dominated by droplet nucleation, it will be shown that the steady state conversion is independent of the reactor configuration.
Keywords:CONTINUOUS EMULSION-POLYMERIZATION;STABILITY;COPOLYMERIZATION;NUCLEATION;OPERATION;STYRENE;SIZE