Reactor Fouling in Emulsion Polymerization

Abstract

Emulsion polymerization is the method of choice for the production of waterborne dispersed polymers used in a broad range of applications including coatings and adhesives. Because of their huge surface area, waterborne dispersed polymers are thermodynamically unstable colloids prone to forming polymer deposits on the reactor wall. Fouling decreases heat transfer, lowering the productivity of the reactors and affecting the quality of the product. Fouling of emulsion polymerization reactors is investigated. It was found that the mere presence of monomer led to an increase in fouling due to the reduction of the glass transition temperature of the monomer-swollen particles. Polymerization caused a strong increase in fouling, and this effect was more pronounced as the amount of monomer in the system increased. The effect was attributed to the formation of unstable polymer particle precursors.

The rise of morphology-engineered microporous organic polymers (ME-MOPs): synthesis and benefits

“…20a and d). 79,80 The polymers sticking on the surface of the reactors induced not only poor quality of polymers but also an increase of costs due to additional efforts to remove the stuck polymers. To solve this problem in polymer production, seed-mediated polymer synthesis can be an efficient way (Fig.…”

On‐line control of emulsion polymerization reactors: A perspective

“…In some cases, such as in seeded systems, early detection of particle coalescence might be possible as the surface coverage of the particles could be estimated from the overall conversion, the number of particles, the solids content, the amount of surfactant in the reactor and the parking area of the surfactant. However, the reduced availability of the surfactant when using non‐ionic [ 52 ] or polymeric [ 53 ] surfactants and the effect shear of coagulation [ 54 ] might complicate the situation.…”

Monitoring Polymeric Fouling in a Continuous Reactor by Electrochemical Impedance Spectroscopy

“…[12] However, in real multiphase systems, the origin of the fouling product is difficult to predict, since both mechanisms interact und run in parallel, as described in [13] and illustrated in [14]. Currently, reaction fouling is being discussed as the mechanism that mainly contributes to fouling [15].…”