The effect of flow regime on the continuous emulsion polymerization of styrene in a tubular reactor

Five isothermal emulsion polymerizations of styrene in a tubular reactor were studied experimentally using an emulsifier concentration in the vicinity of the critical micelle concentration (CMC). The flow regime was characterized by an emulsion Reynolds Number (NRe)e calculated using the emulsion properties prior to any appreciable reaction. It was found that the rate of polymerization was a maximum at the laminar‐turbulent transition based on (NRe)e. This behavior is similar to emulsion polymerizations carried out in batch reactors where a maximum rate of polymerization has been observed when the agitation level (agitator rotation rate) is varied. The controlling mechanisms appear to be similar at high agitation levels but differ when the emulsion is weakly agitated.