Mathematical Modeling of the Production of Elastomers by Emulsion Polymerization in Trains of Continuous Reactors

A mechanistic model is proposed to describe the emulsion polymerization processes for the production of styrene–butadiene rubber (SBR) and acrylonitrile–butadiene rubber (NBR) elastomers in trains of continuous stirred tank reactors (CSTRs). A single model was used to describe both processes by choosing the proper physicochemical parameters of each system. Most of these parameters were taken from literature sources or estimated a priori; only one parameter (the entry rate coefficient) was used as an adjustable value to reproduce the kinetics (mainly conversion), and another parameter (the transfer to polymer rate coefficient) was used to fit the molecular weight distribution (MWD) experimental values from plant data. A 0-1-2 model for the number of particles and for the moments of the MWD was used to represent with more fidelity the compartmentalization effects. The model was based on approaches used in previous emulsion polymerization models published in the literature, with the premise of reaching a compromise between the level of detail, complexity, and practical value. The model outputs along the reactor train included conversion, remaining monomer composition, instantaneous and accumulated copolymer composition, the number of latex particles and particle diameter, polymerization rate, the average number of radicals per particle, average molecular weights, and the number of branches per chain.