Dynamic evolution of the particle size distribution in suspension polymerization reactors: A comparative study on Monte Carlo and sectional grid methods

In the present study, an efficient Monte Carlo (MC) algorithm and a fixed pivot technique (FPT) are described for the prediction of the dynamic evolution of the droplet/particle size distribution (DSD/PSD) in both non‐reactive liquid–liquid dispersions and reactive liquid(solid)–liquid suspension polymerization systems. Semi‐empirical and phenomenological expressions are employed to describe the breakage and coalescence rates of dispersed monomer droplets/particles, in terms of the type and concentration of suspending agent, quality of agitation, and evolution of the physical, thermodynamic and transport properties of the polymerization system. Moreover, the validity of the numerical calculations is first examined via a direct comparison of simulation results obtained by both numerical methods with experimental data on average particle diameter and droplet/particle size distributions for both non‐reactive liquid–liquid dispersions and the free‐radical suspension polymerization of methyl methacrylate (MMA). Additional comparisons between the MC and the FP numerical methods are carried out under different polymerization conditions. The simulation results reveal that both numerical methods are capable of predicting the mean and the distributed particulate properties of both non‐reactive and reactive suspension processes.