Bulk polymerization of styrene in plate and frame batch reactors

Thermal bulk polymerization of styrene in the plate and frame batch reactor i.s simulated with a mathematical model which accounts for chain transfer to monomer and gel effect. The design parameters are: the frame thickness, the temperature policy, and the level of prepolymerization in the feed. The recommended frame thickness with 27% prepolymerization is 5 in. The resulting polydispersities and number average chain lengths range from 2.2–2.3 and 2000–2100 respectively. The implementation of temperature policy, particularly the timing of the application of the coolant, is critical to obtain satisfactory polymer quality. When pure styrene feed is used the reactor displays thermal ignition unless the frame thickness is less then 2 in. For a 5 in. frame prepolymerization should be at least 25 percent to permit adequate temperature control.