Process Intensification of Emulsion Polymerization Using a Compartment Reactor

Abstract

Attempts were made to intensify continuous emulsion polymerization using a compartment reactor consisting of three well-mixing compartments. The goal of this intensification is to obtain a stable and monodisperse particle size as well as high monomer conversion, by controlling the mixing under continuous operation. A two-bladed paddle impeller was used in the first compartment to intensify the dispersibility and reactivity in the aqueous phase, while a rotating disk was used in the third compartment to avoid excessive flocculation of the polymer particles. In the second compartment, a two-bladed turbine impeller or a rotating disk was used. The compartment reactor successfully obtained much higher monomer conversion and also more stable and monodisperse particles than a single continuous stirred-tank reactor. The oscillations of the mean particle size were greatly suppressed by spatially different mixing operations.