Scalability of milli-structured reactors for continuous polymerization

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Staying competitive in the dynamic world of polymers requires constant optimization and innovation, particularly regarding reactors, as their type and operating conditions critically influence the final polymer's quality and application fields. While batch stirred tanks are the conventional choice for polymer production, they suffer from poor heat and mass transfer, high maintenance costs, and scalability issues. Consequently, the chemical industry is shifting towards smart-scaled tubular reactors that operate continuously, facilitating faster, exothermic polymerization with improved surface area-to-volume ratios and shorter diffusion paths. However, miniaturizing reactors introduces challenges such as wall friction and increased viscosity during polymerization, which can lead to laminar flow and negatively impact polymer quality, increasing the risk of fouling. This work investigates the effects of different flow patterns on fouling boundaries and polymer quality, focusing on free radical polymerization of Methyl methacrylate in solvent. Additionally, a significant challenge for smart-scaled reactors is developing effective measurement methods for process parameters like temperature. To address this, Fibre Bragg Grating Sensors have been employed as a less invasive tool for thermal analysis within the reacting system.