60 Polystyrene

this process in a plant that was started in 1955.^ mixtijre_of

styrene and solvent is fed into three polymerization reactors

which are arranged in series (see Figure 4.1»). Each reactor

vessel is fitted with an agitator. The mix in each case enters

the top of the vessel and is passed to the next vessel from the

base.because there-is considerable heat evolved the viscosity

of the solution increases markedly as the reaction proceeds.

Temperature control is again the major problem. (Heat is re-

quired to start the reaction at the top of the first reactor.

Thereafter the problem is to remove the heat of reaction.

Undoubtedly the prime purpose of the solvent is .to aid heat

transfer by keeping viscosity at a reasonable level.y

r^ 'From the reactor the polymer is transferred to a four-stage

devolatilizer vessel held at low pressure by steam ejectors.

Solvent and residual monomer are then removed at 225 °C,

condensed and recycled. To ensure complete removal of both

monomer and solvent in this step the polymer stream is passed

into the devolatilizer through a multi-orifice die to produce

a number of small continuous strands. These strands increase

the surface area thereby increasing the speed of devolatiliza-

tion. The cross-section of the polymer is reduced so that both

monomer and solvent have less distance to diffuse from the

V center to the surface.

After devolatilization the molten polymer is pumped to an

extruder. The material is extruded in strands which are cooled

by being passed through a water bath and chopped by high-

speed rotary cutters.

There are two methods of coloring the finished polymer.

One, colorants are blended with the polymer pellets and the

material is re-extruded; two, a color concentrate is made with

a small amount of polymer and then pumped in molten form

into the main polymer stream immediately after devolatiliza-

tion.

1 British Plastics, p. 26, January 1957.

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