Development of a Computational Framework to Model the Scale-up of High-Solid-Content Polymer Latex Reactors

• Published in: Chemical engineering & technology 2010-11, Vol.33 (11), p.1917-1930
• Main Authors: Pohn, J., Heniche, M., Fradette, L., Cunningham, M., McKenna, T.
• Format: Article
• Language: English
• Subjects: Coagulation; Emulsions; Latex; Polymer latex reactor; Polymerization
• ISSN: 0930-7516; 1521-4125
• DOI: 10.1002/ceat.201000297

A computational framework, consisting of a laminar computational fluid dynamics (CFD) simulation model coupled to a multizonal population balance, is developed to assist in the scale‐up of high‐solid‐content (HSC) latex production and processing. Poly3D CFD software is used to generate flow fields inside a series of reactors; this information is then sent to the process model to assess the impact of nonhomogeneous mixing on the evolution of the latex particle size distribution (PSD) when concentrated latex suspension is altered via the addition of a coagulant. As the general shape of the PSD evolves, the model monitors changes in the rheological parameters in each zone of the reactor; the flow field is recomputed if a significant change in any of the properties is detected. The details of the framework are presented and its utility is demonstrated. Preliminary results indicate that nonhomogeneity inside the reactor will have an effect on the final latex PSD obtained. A hybrid framework, consisting of a laminar computational fluid dynamics (CFD) model coupled to a multizonal population balance, has been developed to assist in the scale‐up of high‐solid‐content (HSC) latex production and processing. The details of the framework which can be used to assess the impact of reactor scale‐up on the evolution of the latex particle size distribution, are presented.