Fouling in Emulsion Polymerization: Fundamentals and Methods of Investigation

ABSTRACT The current understanding of fouling in emulsion polymerization is summarized from an engineering perspective and from a physical‐chemistry perspective. Emulsion polymerization in semibatch mode offers better control over the number of particles and side reactions than batch mode. Both reaction fouling and particulate fouling are observed, the latter being related to coagulation. Thin fouling layers are not necessarily detrimental to the process. The conditions leading to thick layers, which eventually clog pipes, are topics of current research. The fouling material usually is soft because the reaction temperature is above the glass temperature of the polymers involved. At the time for formation, the layers may or may not be compact. They may age by compactification. Special attention is given to modern techniques to monitor fouling in situ. That includes the quartz crystal microbalance with dissipation monitoring (QCM‐D).