Emulsion polymerizations in a pilot-scale loop reactor with inline static mixers

Emulsion polymerizations of methyl methacrylate were carried out in a pilot-scale tubular reactor configured in a batch-loop mode. The tubular sections of the reactor were fitted with in-line static mixers to incite low-shear mixing. The reactor was used to investigate the influence of different recipes and operating conditions on reaction, particularly on the monomer conversion and the polymer particle-size distribution. Experimental data were compared to equivalent bench-scale studies using a conventional stirred flask. A mathematical model was also developed for predicting the temperature dynamics and the conversion of methyl methacrylate polymerization in the pilot-scale reactor. Conversions and particle-size distributions of the pilot-scale loop reactor were found to be very similar to that of the bench-scale studies. The results indicate that in-line static mixers can help to maintain emulsion stability and provide a means for good temperature control, without unduly influencing polymer particle-size distribution. © 2005 American Chemical Society