Patent ID: 8247072

Claim:
A process for producing resol beads having a desired particle size and particle size distribution, the process comprising: a) reacting a phenol with an aldehyde, in the presence of a base as catalyst, in an agitated aqueous medium provided with a colloidal stabilizer, and optionally a surfactant, for a period of time and at a temperature sufficient to produce an aqueous dispersion of resol beads; b) recovering resol beads below a minimum particle size; c) recycling the previously formed resol beads below the minimum particle size into a further aqueous medium of step a) to give a further aqueous dispersion of resol beads; d) optionally separating any beads below the minimum particle size to obtain resol beads above a minimum particle size and further previously formed resol beads below the minimum particle size; and e) optionally recycling any further previously formed resol beads below said minimum size to step c); wherein the previously formed resol beads are not further cured prior to recycling.