Continuous emulsion polymerization: design and control of CSTR trains

During conventional continuous emulsion polymerization of many monomers, sustained oscillations (limit cycles) occur in all latex and polymer properties, creating severe problems commercially. A novel redesigned continuous reactor configuration is clearly shown to eliminate these undesirable oscillations and to offer greatly increase flexibility in controlling particle size and conversion. This control is accomplished by manipulating the initiator feedrate to the first (small) reactor, and the split of the monomer and water feedrates between the small and the first large reactor of the train.