Commercial emulsion polymerization processes are often carried out wit
h high solids (50 percent monomer by weight) recipes, resulting in rel
atively viscous, pseudo-plastic reaction mixtures. The change in rheol
ogical behavior during high solids emulsion polymerization complicates
the process operation in terms of imperfect mixing and reactor foulin
g. This paper discusses the rheology and flow during high solids emuls
ion polymerization of styrene, as well as the effect of particle size
distribution.