Emulsion polymerization kinetics and reactor design. IV. Continuous-flow operation with recycling

A new mathematical model with a correction for radical capturing efficiency in a continuous emulsion polymerization with recycle flow has been proposed. These performance equations predict the conversion as well as molecular weight distribution of the polymer product during the continuous-flow operation. Experimental results obtained with vigorous mixing associated with a premixer are in best agreement with the theoretical prediction. In certain situations, the recycling provides a means for obtaining a higher degree of back-mixing with a normal flow reactor. However, it is difficult to obtain a high conversion of monomer by a continuous emulsion polymerization operation even with a long residence time. Theoretical and experimental average degrees of polymerization of polymer leaving the reactor are progressively displaced toward smaller values with greater mean residence time. According to the calculations based on our kinetic model the ratio M?_w/M?_n in the continuous emulsion polymerization remains constant regardless of mean residence time.     

Hyperbranched polyurethane acrylates synthesized via copolymerization of monomers A2 and B3 with monofunctional compound BR added gradually at different rates

A kinetic model was proposed to describe hyperbranched polymers (HBPs) formed by the polymerization of monomers A₂ and B₃ with monofunctional compound (BR) added gradually in a semibatch reactor. The dependences of the degree of polymerization (DP) and the degree of branching on the reaction time and the monomer compositions were calculated. The DP of the HBPs could be increased by the slow addition of BR in the reactor. If the monomers B₃ and A₂ were mixed at a molar ratio of B₃:A₂ = 1:3, and the BR was fed slowly into the reactor, the HBPs with weight average DP were approximately 3200 and 16 700 at conversion of 0.95 and 0.99, respectively, which were higher than those prepared by the batch system. This theory was further verified by an experimental demonstration. Hyperbranched polyurethane acrylate can be synthesized with a higher DP in a semibatch system than in a batch reactor.     

Modeling of butadiene polymerization using cobalt octoate/DEAC/water catalyst

Two-level fractional factorial designs were employed to study the solution polymerization of butadiene in a batch reactor using cobalt octoate/DEAC/water as catalyst. Conversion and molecular weight data obtained as functions of time were used to develop a kinetic model, and the estimated kinetic parameters were correlated empirically with four operating variables: temperature and concentrations of cobalt octoate, DEAC, and water. The experimental data indicate that at high water concentration a significant amount of oligomers is formed during early stages of polymerization, and the molecular weight of polymer increases with time. Analysis of the data suggests instantaneous initiation, first order propagation with cobalt and monomer, and transfer to monomer. Models which do not take account of the branching are shown to be incapable of fitting data for both M _n and M _w. The catalyst decay seems to follow a first-order mechanism, but the evidence is somewhat inconclusive.     

Free radical polymerization with long chain branching: continuous polymerization of vinyl acetate in t-butanol

Vinyl acetate was polymerized in a continuous stirred tank reactor (CSTR) at 60°C in t-butanol solution. Mean residence times ranged from 1.35 to 7.2 hr; steady state conversions ranged from 15 to 61%. Molecular weights $\text{M}$_n and $\text{M}$_w were measured and interpreted in terms of a kinetic model developed from batch studies and the state of local mixing in the reactor. Good macroscopic mixing was confirmed by tracer studies and measurements of conversion vs time during the start-up period and at steady state. The molecular weights obtained at high conversions agreed more closely with predictions based upon a locally segregated state than with those based on complete molecular mixing. However, calculations based on agitation and diffusion rates raised serious questions about the validity of the segregation model for this polymerization. Other factors, some chemical and some related to the agitation, may be important, but the problem of predicting molecular structure remains unresolved.     

Assessment of kinetics of photoinduced Fe‐based atom transfer radical polymerization under conditions using modeling approach

Kinetic insight into photoinduced Fe‐based atom transfer radical polymerization (ATRP) involving monomer‐mediated photoreduction was performed by modeling approach for the first time. Preliminary numerical analysis of number‐average molar mass (M_n) derivation in this specific system was given. Simulation results provided a full picture of reactant concentration and reaction rate throughout the entire polymerization. Methyl 2,3‐dibromoisobutyrate (MibBr₂) generated from methyl methacrylate (MMA)‐mediated photoreduction as the leading factor for the deviation of M_n from theoretical value was confirmed by reaction contributions in α‐bromophenylacetate (EBPA) containing system. Reasonable predictions were made with respect to the polymerizations under a variety of initial conditions. Results show that increasing light intensity will shorten transition period and increase steady state polymerization rate; decreasing catalyst loading will cause the decrease in polymerization rate and M_n deviation; varying initiation activity will slightly increase the time to attain steady state of dispersity (M_w/M_n) evolution and enormously change the fraction of reaction contributions; increasing targeted chain length will extend transition period, decrease steady state polymerization rate, increase M_n deviation degree with same reaction contributions, and decrease the time to attain the steady state of M_w/M_n. The numerical analysis presented in this work clearly demonstrates the unique ability of our modeling approach in describing the kinetics of photoinduced Fe‐based ATRP of MMA. © 2017 American Institute of Chemical Engineers AIChE J, 2017     

Correlation of low density polyethylene rheological measurements,with optical and processing properties

The processing properties of low density polyethylene melts, such as drawdown and neck-in, and the final product properties, such as film haze and gloss, have been successfully correlated with rheological functions and the level of longchain branching. The rheological functions employed are the entrance pressure drop ΔP_o and the swell ratio S_o, determined at a specified shear stress using aft-orifice with a length/ diameter (L/D) ratio of zero. The calculation of shear stress requires additional measurements using adie with a finite L/D e.g. 20. The rheological functions ΔP_o, and S_o are governed by the level of high molecular weight species and/or the level of long-chain branching(LCB). If determined at a constant shear stress, in order to eliminate the effect of viscosity, they are a relative measure of elasticity. Higher ΔP₀ and S_o indicate a higher level of LCB and correlate with poorer optical properties and drawdown in films.     

Untersuchung des einflusses molekularer parameter auf morphologie und eigenschaften von polyethylenen niedriger dichte

Based on the example of PE-LD grades and on model substances obtained by preparative fractionation (fractions in the molecular weight range M?_w = 1.2 ? 390·10⁴ g/mol), comprehensive investigations regarding the problems of structure/properties have been carried out. The correlations of M?_w with 15 physical and application technological perameters have been investigated taking into account the reaction mechanism during the manufacturing of PE-LD in the tubular and agitated autoclave reactor, resulting in the formation of so-called primary structure perameters M?_n, M?_w, molar mass distribution, short chain branching and long chain branching. For the interpretation of the results, among other factors, also the morphological conditions have been taken into consideration, which in connection with the molecular parameters reveal — for specific M?_w-ranges — strong changes and saturation ranges, resp., for the physical and application technological properties.     

Emulsion polymerization kinetics and its reactor design. II. The MWD behavior in isothermal batch operation

The emulsion polymerization of styrene in an isothermal batch operation can be divided into three stages, and the corresponding kinetic rate equations are obtained from the experimental conversion-reaction time curve. The course of polymerization between the beginning of the reaction and any subsequent time is successfully computed for the reaction rate, the MWD, and the average degree of polymerization using the intergrals of these rate equations, which could readily explain the behavior of the emulsion polymerization. A comparison is made between the theoretical results and the experimental data. Both the theoretical treatment and the experimental data predict that the MWD for a typical emulsion polymerization is characterized by the rapid decrease in M _w/M _w ratio at the entrance of the zero-order stage and a gradual increase in the first-order stage regardless of an autoacceleration effect. An autoacceleration effect in the first-order stage is, however, evidence for a typical emulsion polymerization.     

Flow behavior of well characterized polyethylene melts

A careful characterization and rheological study of low density polyethylene (LDPE) reveals that long-chain branching (LCB) plays a decisive role. At constant molecular weight (M?_w) higher LCB reduces the Newtonian viscosity η_o and the shear sensitivity, increases the activation energy E_o, and finally delays transition to pseudoplastic flow to higher shear rates and the onset of melt fracture to higher shear stresses (τ_d). The flow parameters η_o, \documentclass{article}\pagestyle{empty}\begin{document}$ \dot \gamma _{cr} $\end{document}_cr, τ_d, and the derived flow relaxation times are uniquely correlatable by means of a modified molecular weight (gM?_w) incorporating the LCB effect. High density polyethylene are less shear sensitive than their low-density counterparts, have a lower activation energy, fracture at higher shear stress levels and cannot be regarded as branchless LDPE's.     

Cation effect on gel – sol transition of kappa carrageenan

The steady state fluorescence (SSF) technique was employed to study gel – sol transitions of kappa carrageenan in NaCl, KCl and CaCl₂ solutions. Pyranine was used as a fluorescence probe for monitoring these transitions. Scattered light, I_sc and fluorescence intensity, I was monitored against temperature to determine the gel - sol (T_gs) transition temperatures and exponents. It was observed that T_gs values are strongly correlated to the NaCl, KCl and CaCl₂ contents. The weight average degree of polymerization, DP_w and gel fraction G, exponents (γ and β) were measured and found to be in accord with the classical Flory–Stockmayer Model.     

Kinetics of high conversion polymerization of vinyl acetate. Effects of mixing and reactor type on polymer properties

In the present article the kinetics of polymerization of vinyl acetate in suspension up to high conversion was studied. The molecular weight distribution and the side chain branching of polyvinyl acetate produced were examined with respect to micro and macro mixing as well as to reactor type. The following results were achieved: the time–activity curves of the polymerization can be described up to high conversions considering the exponential increase in viscosity of the polymerizing system and combining the viscosity with rate constants of the polymerization. The change of volume of the polymerizing system has no significant influence on kinetics. The narrowest molecular weight distribution of the poly(vinyl acetate) produced was achieved when polymerizing in the homogeneous continuous stirred tank reactor while the broadest molecular weight distribution was observed in the segregated continuous stirred tank reactor. The batch reactor and the flow tube reactor produce polymers with molecular weight distributions lying in between. Considering the side chain branching, another order was found. The batch reactor and the tube reactor show the lowest side chain branching, the homogeneous continuous stirred tank reactor shows a larger one and the segregated continuous stirred tank reactor shows the largest. Possible reasons for the different behavior of the different reactors are discussed. The degree of segregation was determined by experiments.     

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.     

A radial cell model for a tubular polymerization reactor

A cell model for the prediction of temperature and concentration gradients in a nonisothermal tubular polymerization reactor at steady state is presented. Both radial and longitudinal gradients are considered. The complete molecular weight distribution is calculated as well as the leading moments of the distribution. The model is easily reduced to predict the performance of a plug-flow tubular reactor, batch reactor, and continuous stirred tank reactor (CSTR). The specific polymerization mechanism application consists of free-radical initiation, propagation, and combination termination.     

Long-chain branching in low-density polyethylene

A sample of a commercial low-density polyethylene was fractionated and values of number ? M_n and weight-average M_w, molecular weights obtained together with intrinsic viscosities [η], measured in decalin at 135° and in a theta-solvent, diphenyl at 118°. Results are compared with those obtained using samples of high-density polyethylene, of narrow molecular weight distribution, in decalin at 135° and in diphenyl at 125°. Values of the z-average mean square radius of gyration (S^?2)_z, are converted to the weight-average unperturbed state. The branching parameters g and g¹ thus obtained, indicate that long-chain branching increases with increasing molecular weight. Intrinsic ivscosities under theta-conditions for the low-density polyethylene fractions lead to a relationship [η]_θ = K _w^0·20, agreeing with the treatment of Zimm and Kilb. Some of the approximations involved in the estimation of long-chain branching are discussed.     

Synthesis of branched polyethylene by ethylene homopolymerization with a novel (α‐diimine)nickel complex in the presence of methylaluminoxane

Branched polyethylene (PE) was prepared with a novel (α‐diimine)nickel(II) complex of 2,3‐bis(2,6‐dimethylphenyl)‐butanediimine nickel dichloride {[2,6‐(CH₃)₂C₆H₃? N?C(CH₃)C(CH₃)?N? 2,6‐(CH₃)₂C₆H₃]NiCl₂} activated by methylaluminoxane in the presence of a single ethylene monomer. The influences of various polymerization conditions, including the temperature, Al/Ni molar ratio, Ni catalyst concentration, and time, on the catalytic activity, molecular weight, degree of branching, and branch length of PE were investigated. According to gel permeation chromatography, the weight‐average molecular weights of the polymers obtained ranged from 1.7 × 10⁵ to 6.0 × 10⁵, with narrow molecular weight distributions of 2.0–3.5. The degree of branching in the polymers rapidly increased with the polymerization temperature increasing; this led to highly crystalline to totally amorphous polymers, but it was independent of the Al/Ni molar ratio and catalyst concentration. At polymerization temperatures greater than 20°C, the resultant PE was confirmed by ¹³C‐NMR to contain significant amounts of not only methyl but also ethyl, propyl, butyl, amyl, and long branches (longer than six carbons). The formation of the branches could be illustrated by the chain walking mechanism, which controlled their specific spacing and conformational arrangements with one another. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 1123–1132, 2002; DOI 10.1002/app.10398     

Rheology of metallocene-catalyzed monomodal and bimodal polyethylenes

The effect of molecular architecture on the dynamic viscoelastic properties of new metallocene high density polyethylenes has been analyzed. Bimodal molecular weight distribution metallocene polyethylenes show features different from conventional polydisperse and bimodal polyethylenes. Higher values of Newtonian viscosity (η_o) at the same values of weight average molecular weight (M_w) and stronger frequency dependence of dynamic viscosity (η′) than in conventional HDPE-s have been observed; this leads to lower values of the characteristic frequency for the onset of non-Newtonian behavior (ω_o) and higher values of the power law index (α). These features are probably due to the presence of very small amounts of long chain branching (LCB). The implications of these results in polymer processing are analyzed comparing extrusion rheometer data, which leads to the conclusion that extrusion difficulties in metallocene catalyzed polyethylenes can be overcome with bimodal molecular weight distributions.     

Emulsion polymerization of isoprene. Estimation of the branching exponent with the help of a mathematical model

This work investigates a batch and unseeded emulsion polymerization of isoprene at 10°C with n‐dodecylmercaptan as chain transfer agent (CTA). The obtained polyisoprene (PI) was analyzed by size exclusion chromatography (SEC) with on‐line viscometry. A global polymerization model was adjusted to the measurements of conversion, average particle size, and average molecular weights. The CTA concentration strongly affects the average molecular weights but has a negligible effect on conversion, average particle diameter, and average branching. Due to the combined effects of chain transfers to the polymer and to the CTA, the final molar mass distributions exhibited dispersity indexes higher than 10. The polymerization model predictions on the average degree of branching was combined with an ideal SEC model for adjusting the branching exponent of PI in tetrahydrofuran at 25°C that resulted ε = 2.5. A sensitivity analysis showed that +20% errors in _w induced variations in ε lower than ?10%. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Untersuchungen zur massepolymerisation von vinylchlorid mit dem initiatorsystem tri-n-butylbor/sauerstoff bei −15°C

The system tri-n-butylborone-oxygen was used to initiate the bulk polymerization of vinylchloride at -15°C. The influence of the concentration of tri-n-butylborone, the mole ratio of tri-n-butylborone and oxygen, and the reaction time on conversion, intrinsic viscosity ([η]), and molecular weight (M?_n, M?_w) was investigated. The structure of the PVC-samples with respect to defects and tacticity was determined by means of ¹H-NMR-spectroscopy. The thermal stabilities were established for all the samples. By means of these investigations it was possible to suggest a mechanism of initiation, where the polymerization reaction was mainly initiated by butyl radicals.     

Anionic polymerization of styrene: Integration with styrene monomer production

Anionic polymerization and ethylbenzene dehydrogenation were carried out in the laboratory using continuous reactor designs and conditions typical of current commerical processes. The dehydrogenator was operated at 43–55% conversion with continuous distillation of the ethylbenzene/styrene mixture to remove byproducts that would interfere with the subsequent anionic polymerization. The anionic polymerization was carried out using a reactor of the CSTR type which operated at > 99% conversion of styrene. The volatiles were recovered from the polymer syrup and recycled back to the dehydrogenator. During 4 months of continuous operation the integrated process showed no detrimental buildup of impurities which affected the anionic polymerization or dehydrogenation. The polystyrene produced had excellent color, clarity, thermal stability, and polydispersity (M_w/M_n = 2.1–2.4). The ability to control weight average molecular weight was within a range of 20,000 using an on-line GPC in concert with a colorimeter.