Harnessing Photon Density Wave Spectroscopy for the Inline Monitoring of up to 100 L Vinyl Acetate—Versa® 10 Polymerization: Insights into Dispersion Dynamics and Mixing

Photon Density Wave (PDW) spectroscopy is used as process analytical technology (PAT) in three batch sizes, 1 L, 10 L and 100 L, of polyvinyl acetate-neodecanoic acid vinyl ester (Versa^® 10) copolymerization. The effects on particle formation and growth are comparably analyzed. The data show comparability across scales up to a polymer volume fraction of around 0.15. Deviations beyond this suggest differences in particle growth dynamics. A detailed analysis of the dispersion dynamics and mixing properties provides an enhanced understanding compared to previous studies. Furthermore, the PDW spectroscopy data suggest inhomogeneity due to insufficient mixing at the beginning of the syntheses, despite very low feed-rates of the monomer mixture. PDW spectroscopy is thus capable of monitoring deviations in syntheses at different reaction volumes in real-time. These findings underline the potential of PDW spectroscopy not only for monitoring synthesis but also for enabling inhomogeneity analysis as a new application area. The integration of offline conversion and particle size measurements emphasizes the critical role of mixing efficiency in achieving optimal polymer dispersion properties and final product quality.