Obtain styrene (C8H8), a colorless liquid refined from oil. Styrene monomer is a hazardous material that can only be obtained by licensed professionals. It is a flammable and reactive chemical and a fire and explosion hazard, as well as a carcinogen and a serious health threat if not handled properly. However, styrene also is a natural component in foods such as cinnamon, coffee beans, peanuts, peaches and strawberries, and is harmless in small quantities. Styrene's distinctive odor also can be detected in resin products, such as boat patch materials, and can cause light-headedness.
Add water to the styrene in a reactor at the ratio of 50 percent styrene monomer (by weight), 100 ppm (parts per million) water (based on styrene weight), 2,000 ppm boron trifluoride and an organic solvent. As you can see, very tiny amounts of water are enough to cause a reaction. This process is known as "solution (bulk) polymerization" (there are other methods). A reactor is a container in which the necessary chemicals interact to produce polystyrene, and where the reaction can be monitored and controlled.
Control the temperature of the resulting reaction by removing heat via a jacketing of the reactors with a heat transfer fluid. A jacket is an insulating component of the reactor filled with a liquid that absorbs the heat resulting from the chemical reactions present and transfers it away from the reactor, thus helping control the reaction process. The reactants' temperatures shouldn't vary by more than 60 degrees Fahrenheit throughout the reactor series. The reaction temperature range is 104 to 158 degrees Fahrenheit (40 to 70 degrees Celsius). Tiny droplets of polystyrene will be formed and suspended in solution.
Transfer the batch to a separation station, where the polystyrene is extracted and the waste solvent recycled. The separation station is a large containment device that separates the final styrene product from the solution in which it reacted and was created. Heat the beads and combine with an initiator such as benzoyl peroxide. The droplets combine to forms chains, which in turn combine to form beads. Allow the beads to cool for 24 hours.
Feed the beads into a forming machine. A forming machine determines the shape of the desired product---coffee cups or plates, for example. The addition of heat and pressure allows for the forming of nearly endless shapes and products.