Fouling During Polymerization in Different Continuous Reactor Setups

Fouling in continuous reactors presents a significant challenge in the process intensification of specialty polymers. While in continuous stirred tank reactors (CSTRs) fouling is minimal, tubular reactors experience severe fouling, sometimes leading to complete blockage. Therefore, it is crucial to understand process and design conditions contributing to deposit formation. In this work, the impact of geometry, mixing elements, novel coatings, and ultrasonic waves are tested on tubular reactors for the polymerization of polyvinylpyrrolidone. A series of experimental investigations on the fouling tendency of a solution polymerization in different continuous reactors is presented. Whereas in a continuous stirred tank reactor the polymerization takes place with very little gel formation, heavy deposits form in tubular reactors. Influencing factors are presented and discussed.