Document Type : Research Paper
Authors
1
Polymer Engineering Group, Faculty of Chemical Engineering, Tarbiat Modares University, P.O. Box 14115-143T, Tehran, Iran
2
Department of Polymer Engineering, Sahand University of Technology, P.O. Box 51335-1996, Tabriz, Iran
10.22063/jipst.2024.3511.2275
Abstract
Hypothesis: One of the existing challenges in the foam production industry is to achieve the desired mechanical and thermal insulation properties required, which are directly related to cellular density, size, and distribution of bubbles. Therefore, predicting the bubble size distribution in each foam production system significantly contributes to the final properties of the desired foam. Nucleation, growth, coalescence of bubbles, and their final stabilization are influential stages in the ultimate properties of the foam that should be considered in predicting the bubble size distribution and laboratory testing phase.
Methods: Initially, a modified classical nucleation model was used for predicting cell nucleation, and then a population balance model was employed to predict the size distribution of bubbles in a batch system for the production of polystyrene foam. The modeling of this process was one-dimensional, and changes in bubble diameter were included as the characteristic variable of the system's equations. The foam production stage was carried out at temperatures of 70°C, 90°C, and 110°C, under a pressure of 20 MPa, and the consolidation stage was performed within 0.1 s and 1 s and without consolidation. To calculate the average cell size and size distribution, SEM images and software tools such as Axiovision.v4.82.SP2 and SPSS 26 were used, and the results were compared with the modeling outcomes.
Finding: Using the bubble size distribution obtained from modeling, the average bubble size at a saturation temperature of 70°C and a consolidation time of 1 s was 4.3 µm. With an increase in temperature from 70°C to 90°C, the average bubble size increased to 36.7 µm due to the higher rate of gas diffusion into the bubbles. With an increase in the amount of gas in polystyrene, the free volume increased, and glass transition temperature decreased. At 110°C, the average size of bubble cells increased to 78.1 µm. Since this temperature was higher than the glass transition temperature of polystyrene, in addition to the high gas diffusion rate into the bubble cells, the growth process did not stop, and gas diffusion and coalescence between the bubbles continued. Finally, the model predictions were compared with experiments under various conditions and demonstrated acceptable agreement.
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