Emulsion polymerization of styrene under continuous microwave irradiation

[Display omitted] •Emulsion polymerization of styrene was realized under Microwave (MW) irradiation.•MW power and temperature were kept continuous and constant during the polymerization.•Six process variables were considered to investigate MW effects.•MW accelerated the polymerization rate especially in the initiation stage.•Polymers obtained by MW and conventional heating (CH) methods have similar properties. MW-assisted emulsion polymerization of styrene (M) is examined in this study. Six process variables namely, H2O/M, SDS/M, KPS/M, temperature (T), reaction time (t) and MW power density (P) were investigated in comparison with the conventional heating (CH) method to assess their effects on the polymerization yield and the specific MW energy consumption. An experimental system was designed to keep both T and P continuous and constant during the polymerization. Based on a systematic study, it is found that MW power accelerates the polymerization rate, especially in the initiation step of the polymerization. While 95% conversion was achieved in 40min under P=0.8kWdm−3, 90min was necessary for CH method to reach the same conversion level. Polymers obtained by MW and CH methods under the same process conditions were found to have the same structural and thermal characteristics.