Using a Novel CFD Model to Assess the Effect of Mixing Parameters on Emulsion Polymerization

A novel computational fluid dynamics (CFD) model was developed and validated with the experimental data to explore the effect of the agitator type, rotational speed, and the installation of baffles on the methyl methacrylate conversion, particle size and number of particles of poly methyl methacrylate (PMMA) produced in an emulsion polymerization reactor. The originality of this study was to include the reaction kinetics to the population balance through nucleation and growth rates while taking into account the velocity gradients generated by the impeller rotation inside the reactor. The number density achieved by the Rushton impeller was higher than that for the pitched blade impeller. The distribution of polymer volume fraction was more uniform with the pitched blade impeller than that for the Rushton impeller.

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