A new approach to continuous emulsion polymerization

Abstract

Abstract The application of a continuous Couette‐Taylor vortex reactor to continuous emulsion polymerization was studied. First, the mixing characteristics of the reactor were examined by the stimulus‐response method. It was found that the reactor performance was similar to that of a continuous flow reactor consisting of more than 60 well‐stirred tanks in series if the reactor was properly designed and operated near the critical Taylor number. It was also demonstrated by a comparison of the particle size distributions of the latexes produced in a batch reactor and in the continuous Couette‐Taylor vortex reactor that the continuous reactor could produce latex particles with fairly narrow size distribution. Furthermore, since no stirrer is involved, this continuous reactor is suited for the purpose of avoiding coagulation of latex particles that are very sensitive to mechanical shear.