Particle size distribution control in emulsion polymerization

Effects of the operating policies—the initial initiator amount; the initial emulsifier amount; the monomer addition mode: batch or semibatch; and the monomer addition rate under “monomer‐starved conditions” for the control of particle size distribution (PSD)—were studied through a model that simulates batch and semibatch reactor operations in conventional emulsion polymerization. The population balance model incorporates both the nucleation stage and the growth stage. The full PSDs were reported, which have normally been omitted in earlier studies. It was shown through simulations that the broadness of the distributions, both initial (obtained after the end of nucleation) and final (after complete conversion of monomer), can be controlled by the initial initiator amount and the emulsifier amount. The higher initiator amounts and the lower emulsifier amounts favor narrower initial and final distributions. The shape of the initial PSDs and the trends in the average size and range were preserved with subsequent addition of monomer in the batch or in the semibatch mode, although the final PSD was always considerably narrower than that of the initial PSD. The addition of monomer in the semibatch mode gave narrower distribution compared to that of the batch mode, and also, lower monomer addition rates gave narrower distributions (larger average sizes), which was a new result. It was further shown through simulations that, under monomer‐starved conditions, the reaction rate closely matched the monomer feed rate. These conclusions are explained (1) qualitatively—the shorter the length of the nucleation stage and the larger the length of the growth stage (provided the number of particles remains the same), the narrower is the distribution; and (2) mathematically—in terms of the “self‐sharpening” effect. Experimental evidence in favor of the self‐sharpening effect was given by analyzing the experimental particle size distributions in detail. The practical significance of this work was proposed. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 2884–2902, 2004     

Synthesis of alkyne‐terminated xanthate RAFT agents and their uses for the controlled radical polymerization of N‐vinylpyrrolidone and the synthesis of its block copolymer using click chemistry

Two new alkyne‐terminated xanthate reversible addition‐fragmentation chain‐transfer (RAFT) agents: (S)‐2‐(Propynyl propionate)‐(O‐ethyl xanthate) (X₃) and (S)‐2‐(Propynyl isobutyrate)‐(O‐ethyl xanthate) (X₄) were synthesized and characterized and used for the controlled radical polymerization of N‐vinylpyrrolidone (NVP). X₃ showed better chain transfer ability in the polymerization at 60°C. Molecular weight of the resulted polymer increased linearly with the increase in monomer loading. Kinetics study with X₃ showed the pseudo‐first order kinetics up to 67% monomer conversion. Molecular weight (M_n) of the resulting polymer increased linearly with the increase in the monomer conversion up to around 67%. With the increase in the monomer conversion, polydispersity of the corresponding poly(NVP)s initially decreased from 1.34 to 1.32 and then increased gradually to 1.58. Chain‐end analysis of the resulting polymer by ¹H‐NMR and FTIR showed clearly that polymerization started with radical forming out of xanthate RAFT agent. Living nature of the polymerization was also confirmed from the successful homo‐chain extension experiment and the hetero‐chain extension experiment involving synthesis of poly(NVP)‐b‐polystyrene amphiphilic diblock copolymer. Formed alkyne‐terminated poly(NVP) also allowed easy conjugation to azide‐terminated polystyrene by click chemistry to prepare well‐defined poly(NVP)‐b‐polystyrene block copolymers. Resulting polymers were characterized by GPC, ¹H‐NMR, FTIR, and thermal study. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

(S)-2-(ethyl propionate)-(O-ethyl xanthate)- and (S)-2-(Ethyl isobutyrate)-(O-ethyl xanthate)-mediated RAFT polymerization of vinyl acetate

(S)-2-(Ethyl propionate)-(O-ethyl xanthate) (X1) and (S)-2-(Ethyl isobutyrate)-(O-ethyl xanthate) (X2) were used as the reversible addition-fragmentation chain transfer (RAFT) agents for the radical polymerization of vinyl acetate (VAc). The former showed the better chain transfer ability in the polymerization at 60°C. Kinetic study with both RAFT agents showed pseudo-first order kinetics up to around 85% monomer conversion. Molecular weight of the resulting polymer increased linearly with increase in the monomer conversion up to around 85%. The observed molecular weights calculated from ¹H-NMR spectrum [M_n(NMR)] are close to the corresponding theoretical molecular weights [M_n(theor)]. The corresponding polydispersity index (PDI) of the resulting polymers remained almost constant at around 1.2 up to ∼ 65% monomer conversion and then increased gradually with the further increase in the monomer conversion. Chain-end analysis of the resulting polymers by ¹H-NMR showed clearly that polymerization started with the radical forming out of the xanthate mediator. The negligible homo-chain extension and the hetero-chain extension involving synthesis of poly(VAc)-b-poly(NVP) diblock copolymer were occurred. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Semibatch emulsion polymerization of butyl acrylate. II. Effects of emulsifier distribution

The effects of emulsifier distribution ratio between the initial charge and the feed on particle formation and kinetics of butyl acrylate emulsion polymerization, using sodium lauryl sulfate as emulsifier and potassium persulfate as initiator, were investigated. The number of particles increased with initial emulsifier concentration in the reactor charge. It was shown that traditional ranking, in terms of number of particles produced, of semibatch emulsion polymerization with monomer emulsion feed is not always justified and a semibatch emulsion polymerization can produce far more particles than a conventional batch emulsion polymerization. The number of polymer particles was found to be practically independent of the emulsifier distribution ratio between the charge and the feed for a high overall emulsifier concentration, while for a low overall emulsifier concentration, the number of particles increased with initial loading of the emulsifier. The polydispersity index (PDI) of the final latexes showed a minimum with emulsifier distribution. A bimodal particle size distribution, and a latex with a large PDI, was obtained when there was no emulsifier in the charge. As the initial emulsifier charge increased, a unimodal PSD with a smaller PDI was obtained. With higher proportions of emulsifier in the initial charge, the PDI rose again due to particle nucleation at monomer‐starved conditions, and a skewed unimodal PSD was obtained. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 79: 582–597, 2001     

Semibatch emulsion polymerization of butyl acrylate. I. Effect of monomer distribution

The effects of initial monomer charge on the particle formation and on the rate of polymerization were investigated for semibatch emulsion polymerization of butyl acrylate using sodium lauryl sulfate (SLS) as a surfactant and potassium persulfate (KPS) as an initiator. For the semibatch process with monomer (M) feed, it was found that by varying the monomer distribution ratio between the initial reactor charge and the feed it is possible to alter the contribution of monomer‐flooded and monomer‐starved nucleation mechanisms to the whole nucleation process. The number of particles increases as the initial monomer charge decreases, if the monomer concentration is below a critical value for any fixed system. The increase in number of particles is associated with a broad particle‐size distribution which might depict an emerging second peak on the particle‐size distribution curve. For low emulsifier concentration systems, a larger number of particles was obtained for a lower amount of monomer charge. Particle coagulation and emulsifier adsorption on the monomer droplets were counted as the main reasons for such behavior. For a semibatch process with monomer emulsion (ME) feed, the larger number of particles was formed at a lower initial monomer charge, similar to an M‐add semibatch process. However, the application of monomer charge to an ME‐add process was found to increase the possibility of secondary nucleation and led to the occurrence of a bimodal particle‐size distribution. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 74: 3094–3110, 1999     

Kinetics of NMBA polymerization in a starved feed reactor

A starved feed reactor (SFR) is a semibatch polymerization reactor in which initiator and monomer are fed slowly into a fixed amount of solvent. The polymerization is carried out isothermally at elevated temperatures. The added initiator decomposes instantaneously, and the added monomer polymerizes immediately. The monomer concentration in the SFR is very low, ideally approaching zero. The reactor is in a starved status for reactants. The molecular weight of the product polymer can be effectively controlled by the feed ratio of monomer to initiator. This article presents a study on the kinetics of NBMA polymerization in an SFR. The model parameters were regressed with the experimental data. Although the mass fraction of polymer in the SFR was high (higher than 50%), viscosity was not high and the “gel effect” was weak because of the low molecular weight of the products. It was found that the termination rate constant is a power function of polymer concentration, and the lumped rate constant, k_p/(k)^1/2, can be modeled by the Arrhenius equation. The initiator efficiency, f, remained constant at a temperature less than 120°C, and increased with the temperature increasing at temperatures greater 120°C. The other parameters remained constant in the experiment range. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 81: 2068–2075, 2001     

Poly(dimethylsiloxane‐b‐styrene) diblock copolymers prepared by reversible addition‐fragmentation chain transfer polymerization: Kinetic model

Well‐defined polydimethylsiloxane‐block‐polystyrene (PDMS‐b‐PS) diblock copolymers were prepared by reversible addition‐fragmentation chain transfer (RAFT) polymerization using a functional PDMS‐macro RAFT agent. The RAFT polymerization kinetics was simulated by a mathematical model for the RAFT polymerization in a batch reactor based on the method of moments. The model described molecular weight, monomer conversion, and polydispersity index as a function of polymerization time. Good agreements in the polymerization kinetics were achieved for fitting the kinetic profiles with the developed model. In addition, the model was used to predict the effects of initiator concentration, chain transfer agent concentration, and monomer concentration on the RAFT polymerization kinetics. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Kinetics of butylacrylate polymerization in a starved feed reactor

A starved feed reactor (SFR) is a semibatch polymerization reactor where initiator and monomer are fed slowly into a fixed amount of solvent. The polymerization is carried out isothermally at elevated temperatures. The added initiator decomposes instantaneously and the added monomer polymerizes immediately. The molecular weight of the product polymer can be effectively controlled by the feed ratio of monomer to initiator. This article presents a study on the kinetics of butylacrylate polymerization in an SFR. The model parameters are regressed with experimental data. Although the solids fraction in the SFR is high (>50%), viscosity is not high and the “gel effect” is weak because of the low molecular weight of the products. It is found that the termination rate constant is a power function of molecular weight, and the lumped rate constant k_p/(k)^1/2 can be modeled through an Arrhenius equation. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 93: 1519–1525, 2004     

Miniemulsion polymerisation in pseudo-bulk regime: Mathematical modelling, prediction and optimal strategy of operation

A dynamic mathematical model based on pseudo-bulk kinetics was developed for styrene miniemulsion polymerisation and validated using experimental data. Key findings are that the developed model match reasonably with experimental data and is able to predict the polymerisation attributes and product properties such as fractional conversion, average molecular weight, molecular weight distribution (MWD), average particle size and particle size distribution (PSD) in miniemulsion polymerisation. Optimal strategy of semibatch operation was developed using reaction temperature and monomer feed rate as process variables with specified initial conditions.     

(S)-2-(Ethyl propionate)-(O-ethyl xanthate) and (S)-2-(Ethyl isobutyrate)-(O-ethyl xanthate)-mediated RAFT polymerization of N-vinylpyrrolidone

(S)-2-(Ethyl propionate)-(O-ethyl xanthate) (X1) and the newly synthesized (S)-2-(ethyl isobutyrate)-(O-ethyl xanthate) (X2) were used as the reversible addition-fragmentation chain transfer (RAFT) agents for the radical polymerization of N-vinylpyrrolidone (NVP). The former showed the better chain transfer ability in the polymerization at 60 °C. Kinetics study with X1 shows the psuedo-first order kinetics upto 45% monomer conversion. Molecular weight (M _n) of the resulted polymer increases linearly with increase in the monomer conversion upto around 45%. Polydispersity of the corresponding poly(NVP)s increase gradually from 1.2 to 1.9 with increase in the monomer conversion. Chain-end analysis of the resulted polymer by ¹H NMR shows clearly that polymerization started with radical forming out of xanthate mediator. Living nature of the polymerization was confirmed from the successful homo chain extension experiment and also the hetero-chain extension experiment involving synthesis of poly(NVP)-b-polystyrene amphiphilic diblock copolymer.     

Cationic polymerization in iodine/liquid sulfur dioxide system

Summary Poly(alpha-methylstyrene) with narrow molecular weight distribution (MWD) was obtained by cationic polymerization initiated by iodine in methylene chloride/liquid SO₂ (80/20 vol.%) or toluene/liquid SO₂ (45/55 vol.%) mixed solvent at-60°C. The average number molecular weights of the product polymers increased with monomer conversion but the dependence was not linear because of the low initiation efficiency at the beginning of the reaction. On addition of a fresh feed of monomer at the end of the polymerization, the added feed was polymerized at the same rate with an increase of molecular weight. The low dispersity was kept after the second monomer addition. The initiation efficiency increased during the polymerization.     

RAFT polymerization of styrene mediated by naphthalene-containing RAFT agents and optical properties of the polymers

In this paper, we designed and synthesized five novel reversible addition–fragmentation chain transfer (RAFT) agents bearing naphthyl moieties in the Z or R groups, including 3,4,5-trimethoxy-benzyl dithio-2-naphthalenoate (TOBDN), 4-nitrobenzyl dithio-2-naphthalenoate (NBDN), 1-menaphthyl 4-cyanodithiobenzoate (NCDB), 1-menaphthyl dithiobenzoate (NDB) and 1-menaphthyl dithio-2-naphthalenoate (NDN). The RAFT polymerizations of styrene mediated by these RAFT agents with AIBN as the initiator at 80 °C were conducted and evaluated. Except for NCDB, the RAFT agents showed good control over the polymerization at different RAFT agent concentrations: the M_n,GPC increased linearly with the monomer conversion, and the PDIs of the polymers were relatively low (PDI = 1.20–1.50). The structure of RAFT agents bearing three different R groups with naphthyl as the Z group showed less effects on the polymerization rate, while those bearing different Z groups with 1-menaphthyl as the R group presented significant effects on the polymerization rates. The polymerization rate with phenyl as the Z group was higher than that with 2-naphthyl as the Z group, and it decreased significantly when using 4-cycno phenyl as the Z group. Retardation effects were observed with all the RAFT agents. ¹H NMR spectra and chain extension results confirmed that most of the polymer chains were “living”. Ultraviolet (UV) absorption of naphthyl moieties at the R group showed blue shifts compared with those of naphthyl at the Z group. The UV absorption intensity of PS was uniformly lower than that of the corresponding RAFT agent, while the fluorescence intensity of PS was higher than that of the corresponding RAFT agent.     

Free radical solution oligomerization of styrene in a continuous-stirred tank reactor train

For free radical oligomerization of styrene, a scheme for calculating the molecular weight distribution and conversion in a continuous-stirred tank reactor (CSTR) train is developed, which also allows the calculation of molecular weight distribution (MWD) for batch reaction. Calculations show that under conventional or near dead-end condition: (1) increasing initial initiator concentration, reaction time and reaction temperature, and decreasing initial monomer concentration cause P?_n and P?_w to decrease and MWD to narrow; (2) increasing initial initiator concentration, reaction time and reaction temperature, and increasing monomer concentration cause monomer conversion to increase; (3) a single CSTR gives a lower rate of oligomer production, but a narrower MWD than does a batch reactor.     

Kinetic investigations of acrylic–polyurethane composite latex

The effect of various reaction parameters on the rate of polymerization, R_p, and on the particle size and morphology of aqueous acrylic–polyurethane hybrid dispersions, prepared by semibatch emulsion polymerization, was investigated. The particles of polyurethane dispersion were used as seeds during the polymerization of acrylic component: methyl methacrylate (MMA), butyl acrylate (BA), and a mixture of MMA and BA with the ratio of 1:1. These emulsions were found to form structured polymer particles in aqueous media using scanning electron microscopy. The kinetics of the emulsion polymerization was studied on the basis of Wessling's model. The influence of emulsifier and initiator concentrations, including the monomer feed rates, R_m, on the rates of polymerization and on the properties of the resulting dispersions were studied. The number of particles and the particle size were also measured during the polymerization process. The final values were found to be independent of the concentration of the emulsifier, initiator and the monomer feed rate in monomer starved conditions. In the steady‐state conditions, during the seeded semibatch hybrid emulsion polymerization, the rate of polymerization and the monomer feed rate followed the Wessling relationship 1/R_p = 1/K + 1/R_m. The dispersions MMA/PU, BA/PU, and MMA/BA/PU have K values of 0.0441, 0.0419 and 0.0436 mol/min, respectively. The seeded BA/PU hybrid polymerization proceeded according to Smith‐Ewart Case I kinetics, while the MMA/PU hybrid emulsions demonstrate Case II of the Smith‐Ewart kinetic model. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 2639–2649, 2002     

Surfactant-free aqueous RAFT polymerization of styrene in the presence of CaCO3 particles

A new method to achieve well-controlled surfactant-free aqueous RAFT polymerization of styrene initiated by K₂S₂O₈ in the presence of CaCO₃ particles was proposed. It was found that the hydrophobic monomer of styrene was adsorbed on the surface of CaCO₃ particles and well-controlled surfactant-free aqueous RAFT polymerization mediated with the RAFT agent of S,S′-bis(α,α′-dimethyl-α″-acetic acid) trithiocarbonate (BDMAT) was achieved. The weight ratio of the feeding CaCO₃ to the styrene monomer on the aqueous RAFT polymerization was investigated, and it was found that high CaCO₃/styrene weight ratio led to fast aqueous RAFT polymerization. The aqueous RAFT polymerization kinetics was checked, and the fast RAFT polymerization rate at low molar ratio of styrene/BDMAT/K₂S₂O₈, the linear ln([M]_o/[M])–time plot, the linear increase in the number–average molecular weight with the monomer conversion, and the relatively low PDI values (1.1～1.3) were demonstrated. The surfactant-free aqueous RAFT polymerization was compared with the general emulsion RAFT polymerization in the presence of the sodium dodecyl sulfate (SDS) surfactant. It was found that the surfactant-free aqueous RAFT polymerization seemed more valid than the emulsion RAFT polymerization. The proposed method is believed to be a new strategy to achieve well-controlled surfactant-free aqueous RAFT polymerization.     

Ethylene polymerization over supported titanium‐magnesium catalysts: Effect of polymerization parameters on the molecular weight distribution of polyethylene

The data on the effects of polymerization duration, cocatalyst, and monomer concentrations upon ethylene polymerization in the absence of hydrogen, and the effect of an additional chain transfer agent (hydrogen) on the molecular weight (MW), molecular weight distribution (MWD), and content of vinyl terminal groups for polyethylene (PE) produced over the supported titanium‐magnesium catalyst (TMC) are obtained. The effects of these parameters on nonuniformity of active sites for different chain transfer reactions are analyzed by deconvolution of the experimental MWD curves into Flory components. It has been shown that the polymer MW grows, the MWD becomes narrower and the content of vinyl terminal groups in PE increases with increasing polymerization duration. It is assumed to occur due to the reduction of the rate of chain transfer with AlEt₃ with increasing polymerization duration. The polydispersity of PE is found to rise with increasing AlEt₃ concentration and decreasing monomer concentration due to the emergence of additional low molecular weight Flory components. The ratios of the individual rate constants of chain transfer with AlEt₃, monomer and hydrogen to the propagation rate constant have been calculated. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Kinetic study of radical polymerization. VII. Investigation into the solution copolymerization of acrylonitrile and itaconic acid by real‐time 1H NMR spectroscopy

Free radical solution copolymerization of acrylonitrile (AN) and itaconic acid (IA) was performed with DMSO‐d₆ as the solvent and 2,2′‐azobisisobutyronitrile (AIBN) as the initiator. Weight ratio of the monomers to solvent and molar ratio of initiator to monomers were constant in all experiments. The initial comonomer composition was the only variable in this study. On‐line ¹H NMR spectroscopy was applied to follow individual monomer conversion. Mole fraction of AN and IA in the reaction mixture (f) and in the copolymer chain (F) were measured with progress of the copolymerization reaction. Overall monomer conversion versus time and also compositions of monomer mixture and copolymer as a function of overall monomer conversion were calculated from the data of individual monomer conversion versus time. Total rate constant for the copolymerization reaction was calculated by using the overall monomer conversion versus time data and then k_p/k_t^0.5 was estimated. The dependency of k_p/k_t^0.5 on IA concentration was studied and it was found that this ratio decreases by increasing the mole fraction of IA in the initial feed. The variation of comonomer and copolymer compositions as a function of overall monomer conversion was calculated theoretically by the terminal model equations and compared with the experimental data. Instantaneous copolymer composition curve showed the formation of alternating copolymer chain during copolymerization reaction. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 103: 3253–3260, 2007     

Highly efficient reversible addition–fragmentation chain‐transfer polymerization in ethanol/water via flow chemistry

Utilization of a flow reactor under high pressure allows highly efficient polymer synthesis via reversible addition–fragmentation chain‐transfer (RAFT ) polymerization in an aqueous system. Compared with the batch reaction, the flow reactor allows the RAFT polymerization to be performed in a high‐efficiency manner at the same temperature. The adjustable pressure of the system allows further elevation of the reaction temperature and hence faster polymerization. Other reaction parameters, such as flow rate and initiator concentration, were also well studied to tune the monomer conversion and the molar mass dispersity (?) of the obtained polymers. Gel permeation chromatography, nuclear magnetic resonance (NMR), and Fourier transform infrared spectroscopies (FTIR) were utilized to monitor the polymerization process. With the initiator concentration of 0.15 mmol L^?1, polymerization of poly(ethylene glycol) methyl ether methacrylate with monomer conversion of 52% at 100 °C under 73 bar can be achieved within 40 min with narrow molar mass dispersity (D) ? (<1.25). The strategy developed here provides a method to produce well‐defined polymers via RAFT polymerization with high efficiency in a continuous manner. © 2017 Society of Chemical Industry     

Molecular weight distribution control in a semibatch “living” anionic polymerization. I. Theoretical study

A method to produce homopolymers of preestablished molecular weight distribution (MWD), through “living” anionic polymerizations carried out in homogeneous semibatch reactors is proposed and theoretically justified. In the direct form of the technique, very fast reactions are assumed, and the monomer and “killing” agent feed flows are obtained from the knowledge of the desired MWD, the system spreading function, the total reaction time, the initial reaction volume, and the reagent concentrations. Alternatively, by controlling a reactor outlet flow instead of the “killing” agent feed, an external deactivation of the “living” ends can be implemented. The method can be extended to slow reactions, to more elaborated mechanisms, and to take into account the unwanted deactivation of “living” ends by impurities in the monomer solution feed.     

Population balance modeling of particle size distribution in monomer‐starved semibatch emulsion polymerization

The evolution of particle size distribution (PSD) in the monomer‐starved semibatch emulsion polymerization of styrene with a neat monomer feed is investigated using a population balance model. The system under study ranges from conventional batch emulsion to semicontinuous (micro)emulsion polymerization depending on the rate of monomer addition. It is shown that, contrary to what is often believed, the broadness of PSD is not necessarily associated with the length of nucleation period. The PSDs at the end of nucleation are found to be independent of surfactant concentration. Simulation results indicate that at the completion of nucleation the particle size is reduced and the PSD narrows with decreasing rate of monomer addition despite nucleation time increasing. The broad distribution of particles frequently encountered in semibatch emulsion polymerizations is therefore attributed to stochastic broadening during the growth stage. The zero‐one‐two‐three model developed in this article allows perceiving that the dominant kinetic mechanism may be different for particles with different sizes. © 2009 American Institute of Chemical Engineers AIChE J, 2009