Abstract:
Polystyrene is made by polymerizing a prepared solution of styrene in an inert hydrocarbon liquid e.g. xylene, of boiling point close to that of styrene, under controlled reduced pressure, at a temperature in the range of 50 to 100 DEG C. in the presence of a finely divided sodium catalyst, removing the sodium from the polymer solution, removing the solvent, and if desired subsequently extruding the polystyrene as ribbon or rod and pelletizing it by conventional methods. The solution of styrene is preferably obtained by dehydrogenating ethylbenzene contained in a C8 aromatic stream obtained from hydroformed naphtha and substantially freeing the resulting solution of styrene monomer from tar and water. Natural and/or synthetic rubber may be mixed with the polystyrene either during or after polymerization. The molecular weight of the polymer may be controlled by the addition of an ether modifier such as methylethyl or dimethylether. The solvent is preferably removed by flash distillation and subsequent vacuum treatment. The whole process i.e. from the preparation of the styrene in solution to the pelleting of the polystyrene may be effected continuously and the Specification includes a flow diagram showing this continuous process.