Preparation of polystyrene microspheres by suspension polymerization: A review

Xiao Yafeng; Zhang Yiqing; Dong Zhongtian; Zhou Jun; Ma Shaoping; Wu Shuang; Wang Zhihui; Zhang Qinghua; Yang Chao

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Preparation of polystyrene microspheres by suspension polymerization: A review

Updated：2026-09-17

- Preparation of polystyrene microspheres by suspension polymerization: A review
- Preparation of polystyrene microspheres by suspension polymerization: A review
- 中国化学工程学报（英文） 2026年95卷第7期页码：288-301
- Affiliations：
  
  Department of Chemistry and Chemical Engineering, Xi'an University of Architecture and Technology, Xi'an 710055, China
  College of Design and Engineering, National University of Singapore, 128823, Singapore
  Department of Chemistry and Chemical Engineering, Nanjing University of Science and Technology, Nanjing 210094, China
  State Key Laboratory of Petroleum Molecular & Process Engineering, Institute of Process Engineering, Chinese Academy of Sciences, Beijing 100190, China
  School of Chemical Engineering, University of Chinese Academy of Sciences, Beijing 100049, China
- Author bio：
  
  *Corresponding authors. E-mail addresses:zhoujun@xauat.edu.cn(J. Zhou)
  *Corresponding authors. E-mail addresses:zhhwang@ipe.ac.cn(Z. Wang)
  *Corresponding authors. E-mail addresses:qhzhang@ipe.ac.cn(Q. Zhang).
- Funds：
  
  the Coal-Major Project(2024ZD1700400);the Strategic Priority Research Program of the Chinese Academy of Sciences(XDC0120402);the National Natural Science Foundation of China(22478397;22421003);CAS Project for Young Scientists in Basic Research.(YSBR-038)
- DOI：
  中图分类号：
- 收稿：2025-11-17，
  
  修回：2026-01-11，
  
  录用：2026-01-12，
  
  网络首发：2026-04-13，
  
  纸质出版：2026-07
- Accepted：
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Xiao Yafeng, Zhang Yiqing, Dong Zhongtian, 等. Preparation of polystyrene microspheres by suspension polymerization: A review[J]. 中国化学工程学报（英文）, 2026,95(7):288-301.

Xiao Yafeng, Zhang Yiqing, Dong Zhongtian, et al. Preparation of polystyrene microspheres by suspension polymerization: A review[J]. Chinese Journal of Chemical Engineering, 2026, 95(7): 288-301.
Xiao Yafeng, Zhang Yiqing, Dong Zhongtian, 等. Preparation of polystyrene microspheres by suspension polymerization: A review[J]. 中国化学工程学报（英文）, 2026,95(7):288-301. DOI：

Xiao Yafeng, Zhang Yiqing, Dong Zhongtian, et al. Preparation of polystyrene microspheres by suspension polymerization: A review[J]. Chinese Journal of Chemical Engineering, 2026, 95(7): 288-301. DOI：

摘要

Abstract

Polystyrene microspheres are widely utilized in automobiles

electronics and packaging due to their diverse characteristics

which are highly dependent on particle size. Traditionally

with the manipulation of suspension polymerization parameters

different sizes of microspheres ranging from 10 to 1000 μm can be prepared

with the coefficient of variation (CV) of particle size distribution ranging from 20% to 50%. However

emerging application fields such as pharmaceuticals and biotechnology have high demands for stability and require a narrow particle size distribution. To address this

researchers have proposed novel approaches. This review summarizes both well-developed traditional methods and emerging techniques for particle size control

analyzing their underlying mechanisms. The aim is to provide a reference for the development of preparation methods with controllable particle size. Firstly

the mechanisms of traditional particle size control methods

including optimization of stirring parameters

design of dispersant systems

regulation of oil-to-water ratio

utilization of salt effects and temperature control

are analyzed

and the mechanism of these methods in modulating microspheres size is concluded. Secondly

novel techniques such as membrane emulsification

microfluidic technology and acoustic field-assisted methods in controlling particle size distribution and enhancing reaction efficiency are introduced

mainly focused on their principle characteristics and potential application prospects. Finally

the future development of suspension polymerization technique in preparation of polystyrene microspheres is discussed.

关键词

Keywords

references

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