Application of the plug flow with axial dispersion model for continuous emulsion polymerisation in a pulsed packed column

The performance of a pulsed packed column (PPC) has been investigated for the continuous emulsion polymerization of styrene. In a PPC, good local agitation is combined with little backmixing. Good local agitation provides proper emulsification, intensive radial mixing and high rates of heat transfer to the reactor wall. As a result of the low backmixing in the PPC, sustained oscillations in conversion and particle number, which are often observed in a CSTR, can be avoided completely. This indicates that the PPC is a promising reactor for continuous emulsion polymerization and that the performance of the PPC can be predicted by a steady-state model. In this study a comprehensive steady-state model has been derived for the continuous production of seed latexes in a PPC. The model is based on micellar nucleation and plug flow with axial dispersion. A rate equation for particle nucleation has been derived from batch experiments. It has been shown for the emulsion polymerization of styrene that there is a good agreement between simulations with the developed model and experiments in the PPC.