Methods and apparatus for controlled single electron transfer living radical polymerization

A method of conducting a continuous SET-LRP process said method comprising:

• (i) charging a reactor system with a polymerizable reaction fluid comprising at least one polymerizable (meth)acrylate monomer, at least one solvent for said monomer, a metal salt, at least one ligand and at least one initiator;
• wherein said reactor system comprises a reaction vessel configured for continuous polymer production, with said reaction vessel comprising a catalytic surface wherein said catalytic surface is of copper or comprises copper which has been pre-treated with a reducing agent and has sufficient catalyst present to convert said polymerizable reaction fluid to a radical living polymer having a polydispersity of 1.4 or less;
• (ii) running a continuous SET-LRP reaction in said reaction vessel for a time and at a temperature sufficient to produce a desired level of polymer conversion having said polydispersity;
• and
• (iii) isolating said polymer.