Suspension polymerization of unsaturated polyester-styrene was carried out in different media using different routes of polymerization. The effects of matrix type and concentration hold up, viscosity, irradiation dose, and the agitation speed on the resultant polymer characteristics were examined. The formed beads were physically identified using scanning electron microscopy, hardness, and particle size analysis techniques. They were smooth having typical spherical surfaces; the beads diameters were in the range of about 5-200 pm. The size of the resin beads was found to decrease with increase in the concentration and viscosity of the dispersant and impellers speed. The resultant beads were applied in the recovery of Li+, Na+, K+, and Cs(+)ions from acidic media. The distribution coefficients of the alkali metal ions were calculated; the order of selectivity was Li+ > Na+ > K+ > Cs+ in case of the chemically processed resin beads, while the selectivity lies in the order of Li+ < Na+ < K+ < Cs+ in case irradiation processed ones. Finally, the economics of production of the unsaturated polyesterstyrene resins using different methodologies was studied. (c) 2007 Wiley Periodicals, Inc.