Abstract: Disclosed is a reactor or sparging vessel suitable for use for reaction mixtures containing vapor and/or gas bubbles. It comprises a mechanical agitation means suitable to redistribute flow radially and at least one perforated plate suitable to provide resistance to axial flow. In desirable embodiments it may include at least one electrically or hydraulically-stimulated rotatable shaft upon which at least one blade impeller is mounted, and at least one perforated plate oriented such that it provides resistance to axial flow. The perforated plate may have channels therethrough whose cross-sectional dimension is smaller than the projected average diameter of the vapor and/or gas bubbles. The reactor or sparging vessel offers improved flow dynamics, including reduced back mixing and narrowed residence time distribution. A method of employing the reactor for a reaction mixture containing vapor and/or gas bubbles is also disclosed. An impeller blade having two curvatures is also disclosed.

Abstract: A continuous process for producing high impact polystyrene comprising feeding at least one vinyl aromatic monomer, an elastomer, and a free radical initiator to a first linear flow reactor to form a reaction mixture, polymerizing the reaction mixture in said linear flow reactor to at least the phase inversion point of the mixture, and feeding the reaction mixture from the first linear flow reactor to a second reactor for post-inversion polymerization of the mixture. A method of producing an elastomer-reinforced polymer comprising inverting a reaction mixture comprising at least one vinyl aromatic monomer, an elastomer, and a free radical initiator in a plug flow reactor. A high impact polystyrene reactor system, comprising a linear flow reactor having an inlet and an outlet, and a continuously stirred tank reactor having an inlet in fluid communication with the linear flow reactor outlet and receiving an effluent from the linear flow reactor.

Abstract: Disclosed is a composition comprising an impact modified polystyrene prepared using a process comprising dissolving a styrene-butadiene-styrene block copolymer in styrene monomer and polymerizing the styrene monomer wherein the impact modified polystyrene has a haze value of less than or equal to 12 percent. Also disclosed is an impact modified polystyrene prepared using the same process and having a ratio of Mz/Mn of at least 4.1.

Abstract: A method for removing heat from a horizontal linear flow reactor, comprising introducing vapor bubbles into a liquid medium in the reactor and removing the vapor from the reactor. A method of producing an elastomer reinforced polymer comprising autorefrigerating the reactants in a horizontal linear flow reactor in which both initial polymerization and phase inversion occur. A method of removing heat from a horizontal plug flow reactor comprising aerating the reactants within the reactor, wherein the aeration promotes radial mixing of the reactants but does not substantially promote axial mixing of the reactants. A horizontal linear flow reactor, comprising a horizontal reaction chamber having one or more mechanical flow facilitators disposed therein and a sparger attached to the bottom of at least a portion of the reaction chamber.

Abstract: A continuous process for producing high impact polystyrene comprising feeding at least one vinyl aromatic monomer, an elastomer, and a free radical initiator to a first linear flow reactor to form a reaction mixture, polymerizing the reaction mixture in said linear flow reactor to at least the phase inversion point of the mixture, and feeding the reaction mixture from the first linear flow reactor to a second reactor for post-inversion polymerization of the mixture. A method of producing an elastomer-reinforced polymer comprising inverting a reaction mixture comprising at least one vinyl aromatic monomer, an elastomer, and a free radical initiator in a plug flow reactor. A high impact polystyrene reactor system, comprising a linear flow reactor having an inlet and an outlet, and a continuously stirred tank reactor having an inlet in fluid communication with the linear flow reactor outlet and receiving an effluent from the linear flow reactor.

Abstract: Disclosed is a reactor or sparging vessel suitable for use for reaction mixtures containing vapor and/or gas bubbles. It comprises a mechanical agitation means suitable to redistribute flow radially and at least one perforated plate suitable to provide resistance to axial flow. In desirable embodiments it may include at least one electrically or hydraulically-stimulated rotatable shaft upon which at least one blade impeller is mounted, and at least one perforated plate oriented such that it provides resistance to axial flow. The perforated plate may have channels therethrough whose cross-sectional dimension is smaller than the projected average diameter of the vapor and/or gas bubbles. The reactor or sparging vessel offers improved flow dynamics, including reduced back mixing and narrowed residence time distribution. A method of employing the reactor for a reaction mixture containing vapor and/or gas bubbles is also disclosed. An impeller blade having two curvatures is also disclosed.

Abstract: The selection of additives to improve the solubility of blowing agents may be facilitated by using a method that involves determining and comparing the activity coefficients of prospective additives to the activity coefficients of candidate blowing agents in a given base polymer for producing a polymeric foam article. The method for the selection of an additive may comprise selecting a representative compound for the base polymer and determining a first activity coefficient for a blowing agent in the representative compound. Also selected are several candidate additives, each having a different functional group, and determining a second activity coefficient for the blowing agent in each of the candidate additives. Among the candidate additives is selected the additive, wherein the second activity coefficient is lower than the first activity coefficient. The method may be incorporated into a process for forming polymeric foams and the manufacture of a polymeric foam.

Abstract: Disclosed is a composition comprising an impact modified polystyrene prepared using a process comprising dissolving a styrene-butadiene-styrene block copolymer in styrene monomer and polymerizing the styrene monomer wherein the impact modified polystyrene has a haze value of less than or equal to 12 percent. Also disclosed is an impact modified polystyrene prepared using the same process and having a ratio of Mz/Mn of at least 4.1.

Abstract: The selection of additives to improve the solubility of blowing agents may be facilitated by using a method that involves determining and comparing the activity coefficients of prospective additives to the activity coefficients of candidate blowing agents in a given base polymer for producing a polymeric foam article. The method for the selection of an additive may comprise selecting a representative compound for the base polymer and determining a first activity coefficient for a blowing agent in the representative compound. Also selected are several candidate additives, each having a different functional group, and determining a second activity coefficient for the blowing agent in each of the candidate additives. Among the candidate additives is selected the additive, wherein the second activity coefficient is lower than the first activity coefficient. The method may be incorporated into a process for forming polymeric foams and the manufacture of a polymeric foam.

Abstract: A method and apparatus for use in making high impact polystyrene by polymerizing butadiene into polybutadiene, continuously exchanging styrene monomer for the solvent used to produce the polybutadiene, and polymerizing the resultant polybutadiene/styrene solution into high impact polystyrene. Apparatus is disclosed that includes butadiene and solvent preparation means, additive metering means, butadiene polymerization means, solvent exchange means, solvent recovery means and styrene polymerization means.