Dynamic Modelling of the Emulsion Copolymerization of Styrene/Butadiene

Abstract

<p> A computer model is developed to simulate the emulsion copolymerization of styrene/butadiene in perfectly stirred batch, semi-batch or continuous flow reactors. The model considers free radical initiation by a redox mechanism, micellar particle nucleation, radical concentration as -a function of particle size, radical entry rate and termination rate and diffusion controlled termination and propagation reactions. It predicts conversion, copolymer composition, particle number, number and mass average molecular masses and tri- and tetra-functional branch frequencies. A simple method of estimating the particle size distribution is included in the model. Heat balances over the reactor and cooling jacket are considered and proportional-integra control of the reactor temperature is simulated.</p> <p> The model is used to simulate SBR copolymerization and styrene homopolymerization experimental data from the literature. These simulations tested only certain parts of the model and it is concluded that a more complete verification of the model can only be achieved by running a series of designed experiments. Qualitatively, the molecular mass, particle size distribution and reactor temperature predictions appear to be reasonable. The lack of appropriate temperature dependent rate constants currently limits the molecular mass predictions to isothermal conditions.</p> <p> A comparison of semi-batch operating policies designed to control copolymer composition is presented to illustrate the potential application of the model.</p>