Emulsion polymerization of styrene: Simulation the effects of mixed ionic and non-ionic surfactant system in the presence of coagulation

A detailed model was developed for emulsion polymerization of styrene in batch reactor to predict the evolution of the product particle size distribution. The effect of binary surfactant systems (ionic/non-ionic surfactants) with different compositions was studied. The zero–one kinetics was employed for the nucleation rate, with the model comprising a set of rigorously developed population balance equations. The modeling incorporated particle formation by both nucleation and coagulation phenomena. The partial differential equations describing the particle population were discretized using finite volume elements. Binary surfactant systems, comprising sodium dodecyl sulfate (SDS) as anionic, and a commercial polyether polyol (Brij35®) as non-ionic surfactants, were examined with different mass ratios. Increasing non-ionic surfactant mass fraction in binary surfactant system showed the decrease of particle number due to intensifying the coagulation between particles. Broader particle size distributions with greater average particle size were obtained with non-ionic surfactant comparing those obtained with anionic one.

► Mixed surfactant systems (SDS as anionic, and Brij35® as non-ionic surfactants) affects the PSD, conversion.
► Number of particles for emulsion polymerization of styrene in a batch reactor.
► Model is developed on the basis of population balance equation considering the polydispersity of particle sizes.
► New model is developed to total rate of coagulation in mixed surfactant systems with diverse ionic/nonionic compositions.