A Continuous Synthesis of Polymethylmethacrylate Using a Microreactor Plant

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We applied a microreactor to the synthesis of polymethylmethacrylate (PMMA) using a laboratory microreactor system with a production volume of 2–3 t per year, which enabled pseudo-continuous feeding by syringe pumps. When using a tube made of stainless steel, the values of the yield, number average molecular weight (Mn), and polydispersity index (PDI) reached 75.2%, 9.4×103, and 1.88, respectively. These results were in good accordance with the reported ones and a product with comparable properties was obtained. Then, we performed a continuous synthesis of PMMA for 8 h using a medium scale microreactor plant with a production volume of 100 t per year, which provided continuous feeding by triple cam driven pumps. When using a tube made of polytetrafluoroethylene (PTFE), it was confirmed that a product was continuously obtained for 8 h, whose yield, Mn, and PDI were on average 66.2%, 8.8×103, and 1.95, respectively. The variation in the yield, Mn, and PDI was within 5.7%, 4.5%, and 1.0%, respectively. For comparison, when using the laboratory microreactor system under the same reaction condition with a tube made of PTFE, the corresponding values of the yield, Mn, and PDI were 66.5%, 8.4×103, and 2.04, respectively. The difference in the results between the above two microreactor systems was 4.8% at a maximum (in Mn). Therefore, the synthesis of PMMA was continuously performed using the medium scale microreactor plant and the comparability of the reaction performance between the above two microreactor systems was ensured.

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