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Suspension Polymerization!
! The suspension polymerization process is typically carried out in wellstirred batch reactors! ! ! The volume of the reaction vessel can be up to 150 m3! The monomer(s) is (are) initially dispersed in the continuous phase (commonly water) by the combined action of surface active agents (inorganic or/and water-soluble polymers) and agitation! ! All the reactants (monomer(s), initiator(s), etc.) reside in the organic or oil phase!
Suspension Polymerization!
! The polymerization occurs in the monomer droplets that are progressively transformed into sticky, viscoelastic monomerpolymer droplets and nally into rigid, spherical polymer particles in the size range of 50500 m! ! The polymer solids content in the fully converted suspension is typically 3050% w/w! ! In the inverse suspension polymerization, the hydrophilic monomer(s) (e.g., acrylamide, acrylic acid) and initiator are dispersed in the hydrophobic continuous organic phase (e.g., hexane, parafn oil)!
Suspension Polymerization!
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Control of PSD!
! In general, the initial monomer droplet size distribution (DSD) as well as the polymer PSD depends on the type and concentration of the surface active agent, the quality of agitation (e.g., reactor geometry, impeller type, power input, etc.) and the physical properties (e.g., densities, viscosities, interfacial tension) of the continuous and dispersed phases! ! The dynamic evolution of the droplet/PSD is controlled by the rates of two physical processes, namely, the drop/particle breakage and coalescence!
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Control of PSD!
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Control of PSD!
Droplet breakage:! ! Mainly occurs in regions of high shear stress (i.e., near the agitator blades) or as a result of turbulent velocity and pressure uctuations along the drops surface! Drop/particle coalescence! ! ! Can be increased / decreased by the turbulent ow eld! At sufciently high concentrations of surface active agents, it can be assumed to be negligible for very dilute dispersions!
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Control of PSD!
The suspension polymerization process can be divided into three stages! ! At low monomer conversions (i.e., low viscosity of the monomerpolymer phase, stage one), drop breakage is the dominant mechanism! ! During the second sticky-stage of polymerization, the drop breakage rate progressively decreases while drop/particle coalescence becomes the dominant mechanism! ! At higher monomer conversions, the particles are sufciently hard so the collisions between them are elastic and, thus, the particle coalescence ceases (identication point)! ! After this point, the PSD has been established!
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Droplet size!
Dependence of the steady-state Sauter mean diameter on the agitation speed for (a) various PVA grades and (b) concentrations!
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EPS!
! Suspension polymerization in the presence of a blowing agent (e.g., pentane)! ! It is also possible to introduce the blowing agent to the polymer after polymerization and allowing it to diffuse into the beads!
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EPS!
! Once the beads are hard, the reaction mixture is heated to a temperature above the glass transition temperature of the PS, 100C! ! During heating, the reactor is pressurized with a blowing agent (usually npentane) at 58% w/w! ! Subsequently, the reactor is pressurized with nitrogen at 79 bars and the so-called impregnation stage starts! ! ! n-pentane diffuses into the beads! The system is cooled down to 2030C, so that no bead expansion can take place during the discharge! ! In the next stage, the excess of stabilizer is chemically removed!
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EPS!
! In the nal processing, the EPS beads are warmed up to 80110C, generally with steam that causes the beads to expand by foaming and their volume to increase by a factor of 3050!
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Above a critical monomer conversion (i.e., xc 30%) the volume contraction of the polymerizing particles stops, which partially explains the appearance of internal particle porosity!
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Commercial-scale suspension reactors have to perform several functions simultaneously! Dispersion, reaction and heat transfer (do not scale-up in the same manner)!
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Evolution of PSD!
Dynamic evolution of the PSD with respect to polymerization time for VCM suspension polymerization! TP: 56.5C! Impeller speed: 330 rpm! Dispersed phase volume fraction: 40%!
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Evolution of PSD!
Dynamic evolution of the Sauter mean diameter of PVC particles with respect to polymerization time!
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