Preparation of phenolic resin spheres by suspension polymerization technique: Effect of agitation rate

Spherical resin particles have been prepared from resole type phenolic resin by suspension polymerization technique. The particles were prepared using different agitation rate and a significant change in the particle size & its distribution was observed with respect to agitation rate. The yield of particle size ranging 0.85-1.4 mm decreases from 83.8 % to 20.2 % whereas the yield of particle size ranging 0.43-0.85 mm increases from 15.0 % to 66.5 % on increasing agitation rate from 450 RPM to 650 RPM. Size of phenolic resin spheres depend on the mechanical force, produced by stirrer, acting across the dispersed resin particles. The present study reveals that the required particle size of phenolic resin spheres may be obtained by changing only agitation rate keeping other process parameters constant. These particles are useful for making microporous activated carbon spheres with high surface area and good mechanical strength.