A Simulation-Driven Strategy for Improved Expandable Polystyrene Synthesis via Multi-Stage Initiator Dosing

• Ojochide P. DAMIAN

  Department of Chemical Engineering, University of Abuja, Abuja, Nigeria

  Author

• Fadimatu N. DABAI

  Department of Chemical Engineering, University of Abuja, Abuja, Nigeria

  Author

• Abdulwasiu ABDURRAHMAN

  Department of Chemical Engineering, University of Abuja, Abuja, Nigeria

  Author

• Kamiludeen OLANREWAJU

  Department of Nuclear Engineering, University of Abuja, Abuja, Nigeria

  Author

• Bilyamin ABDULMUMIN

  Department of Chemical Engineering, Ahmadu Bello University, Zaria, Nigeria

  Author

• Grace A. OLUGBENGA

  Department of Chemical Engineering, University of Abuja, Abuja, Nigeria

  Author

This project study compares two initiator dosing strategies, Single Stage Initiator Dosing (SSID) and Multi Stage Initiator Dosing (MID), for producing expandable polystyrene (EPS) via free radical polymerization, simulated using Aspen HYSYS. The analysis focused on reaction kinetics, molecular weight distribution (MWD), yield, energy consumption, and environmental performance. Both strategies achieved polydispersity indices (PDI) close to 2.0, confirming the expected behavior of free radical polymerization. SSID produced longer polymer chains (Mn = 15,342.9 g/mol; Mw = 30,372.2 g/mol), which may enhance mechanical strength but reduce foam uniformity. In contrast, MID achieved a uniform PDI of 2.00 with shorter chains, offering tighter control and more consistent foam properties. SSID required less energy due to its simpler setup, whereas MID consumed slightly more energy because of longer residence times. However, MID outperformed SSID environmentally by minimizing unreacted styrene and volatile organic compound (VOC) emissions. The simulation indicated that neither method produced toxic liquid waste. Overall, the results highlight MID as the more robust and scalable pathway for modern EPS production, offering a balanced approach to efficiency, product consistency, and sustainability. Nevertheless, SSID remains relevant in contexts where simpler setups and strict control over chain length are prioritized. These insights provide both quantitative and qualitative foundations for selecting initiator dosing strategies in industrial EPS process design.

• FJET_12_66_59

Copyright (c) 2025 FUDMA Journal of Engineering and Technology

This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.