Strategies for optimisation and control of molecular weight and particle size distributions in emulsion polymerisation

Abstract

Publisher Summary Emulsion polymerization is widely used in industries to produce products ranging from adhesives to surfboards. The process is preferred because the reaction medium (usually water) facilitates agitation, heat and mass transfer, and provides an inherently safe process. Emulsion polymerization reactor dynamics were modeled with a focus on the computation of molecular-weight distributions (MWD) and particle-size distributions (PSD). The evolution model equations included the detailed kinetics of styrene polymerization in a semibatch reactor through free-radical mechanism. The effects of variations in temperature, feed-rate, and monomer and surfactant concentrations on the molecular weight, particle size, and polydispersity indices are investigated. The operating temperature and monomer and surfactant feed rates are found to have significant effects on the MWD and PSD. Based on findings, strategies for controlling the MWD and PSD are formulated.