Current Polystyrene Polymerization Processes

Reactor type Polymerizing system Advantages Disadvantages Economics 

Continuous solution Free radical (backmixed reactor) Styrene monomer Recycled solvent W or W/O initiator Good Temperature Control Good for copolymers Good clarity and color Uniform product Limited in final conversion Limited in product range Pumping difficulties High capital Low-cost process for high-volume GP 

Batch or continuous Suspension free radical Styrene monomer Water carrier Stabilizing agent Several initiators Excellent heat control High conversion No devolatilization Good range of products Need prereactor for HIPS Poorer clarity Poor uniformity Round beads are hazard High operating costs Better for low-volume products 

Continuous solution Anionic Pure styrene monomer Much recycled solvent Anionic initiators Polymerize to completion Low residual monomer High polymerization rate Good for spec, copolymer Sensitivity to impurities Initiator cost Color of product Cannot produce HIPS Not proven for high-volume GP 

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EPR is currently replaced by EPDM, a modification with a diene monomer, due to its improved workability. A novel type of elastomer (called a thermoplastic elastomer) exhibits quite revolutionary behavior. Here cross-linking is temporary (at room temperature) while it can flow at higher temperatures, like thermoplastics. The typical one (SBS) is a strictly ordered block copolymer of styrene and butadiene, made by an anionic polymerization. The butadiene chains (at a controlled MW of 70,000) are embedded in a rigid phase of polystyrene spheres (MW of 15,000) thus providing temporary cross-linking at ambient conditions, while being processible at high temperatures like thermoplastics. 

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