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     

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     

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     

Semibatch anionic ring‐opening polymerization of octamethylcyclotetrasiloxane in emulsions: effect of the amount of seed polymer particles

Semibatch anionic ring‐opening polymerization of octamethylcyclotetrasiloxane with the use of seed polymer particles in emulsions was studied. The concentration of the emulsifier was set above the critical micelle concentration. We investigated the effect of the amount of seed polymer particles on the chemical kinetics and the average particle size and distribution. During monomer starving conditions the polymerization rate strongly depended on the monomer feed rate and not on the amount of seed particles. Throughout the entire monomer feed period the average particle size increased. This increase depended on the number and the size of seed particles. In emulsions with higher particle sizes higher equilibrium conversions were obtained. In our opinion, a greater extent of backbiting reactions is responsible for lower equilibrium conversions during and at the end of the process. The seeded semibatch process seems a reasonable choice for designing emulsion products with high monomer conversion and desired particle size. © 2012 Society of Chemical Industry     

Study of different types of monomer emulsion feedings to semibatch emulsion polymerization reactors

Semibatch emulsion polymerization processes with a monomer emulsion feed are of great importance in both academia and industry. Monomer emulsion feeds can be applied to semibatch reactors using either a stream of an emulsified monomer or two streams of a neat monomer feed and an aqueous solution of an emulsifier. The effect of the feeding policy on the rate of polymerization and on the secondary particle formation was studied for a seeded semibatch emulsion polymerization of styrene. When a single-stream monomer emulsion feed is applied to a semibatch process, the monomer-swollen micelles formed in the feed might become the locus of initiation upon entering the reaction vessel. Under the conditions of this study, the application of monomer emulsion feed in either one stream or two streams did not result in secondary particle formation. The incoming monomer-swollen micelles were disintegrated to supply emulsifier molecules for the stability of growing particles, before they can capture radicals and become polymer particles. The rate of polymerization was found to be independent of the way that the monomer emulsion feed is added. In the absence of nitrogen, the rate of polymerization decreased more appreciably for the monomer emulsion feed, due to the oxygen dissolved in the emulsified monomer. The number of particles, however, was not affected by the purging policy. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 82: 2472–2477, 2001     

Semibatch anionic ring-opening polymerization of octamethylcyclotetrasiloxane in emulsion

The semibatch anionic ring-opening polymerization of octamethylcyclotetrasiloxane in emulsion was studied under the condition of no seed particles used in polymerization system. Concentration of emulsifier was set above critical micelle concentration. Effect of monomer feed rate on the chemical kinetics, average particle size and distribution and on the polymer molar mass and distribution was investigated. During monomer addition, polymerization rate was constant and controlled by the monomer feed rate. According to the proposed mechanism for anionic polymerization in emulsion, it was assumed that also the number of active polymerization sites and monomer concentration at the particle surface, where propagation occurs, remain constant. A continuous increase of average particle size and absence of extensive condensation reactions at high conversion suggested that the freshly added monomer diffuses toward hydrophobic polymer particles, where it is consumed in propagation reaction and/or accumulated in the particle core.     

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     

Thiol-ene emulsion polymerization using a semi-continuous approach

The thermally initiated thiol-ene emulsion polymerization of diallyl phthalate (DAP) diene and ethylenedioxy diethanthiol (EDDT) dithiol monomers in batch and semibatch emulsion polymerization is investigated. The batch process leads to larger and broader particle sizes than when the polymerization is carried out in semibatch. The evolution of the particle size and the final particle size distribution indicate that the stability of the latexes is limited and, hence, aggregation phenomena occurred in both processes. In particular, the evolution of the particle size distribution (PSD) in the semibatch process indicates nucleation, growth, and aggregation occurring simultaneously that produced a bimodal particle size. When the diene monomer was changed to diallyl terephthalate (DATP), the semibatch polymerization yielded smaller particles and narrow distribution without any indication of aggregation. The partial substitution of the dithiol by a trithiol monomer that is substantially more water insoluble affected nucleation of the particles, yielding for both systems smaller particles. The polythioether polymers synthesized present low glass transition temperatures (~ −30/−40°C) and those containing the therephthalate yield crystalline films. The potential application of the polymers as pressure sensitive adhesives (PSAs) was preliminarily assessed.     

Semibatch emulsion copolymerization of methyl methacrylate and butyl acrylate

The concentration of sodium lauryl sulfate (SLS) in the initial reactor charge is the most important parameter in determining the particle size of a semibatch emulsion copolymerization of methyl methacrylate (MMA) and butyl acrylate (BA). The number of particles formed is proportional to the concentration of SLS to the 0.5–1.2 power and it is proportional to the concentration of the nonyl phenol–40 mol ethylene oxide adduct to the 0.014–0.72 power. The number of particles is almost independent of the concentration of the initiator. The solubility of monomer in water has an important effect on the nucleation mechanism according to the literature. However, the ratio of MMA to BA does not show any significant effect on the latex particle size in our laboratory. The particle size also increases with increasing ionic strength or agitation speed. Experimental data of particle-size distribution and molecular weight distribution support the coagulative nucleation mechanism when the concentration of SLS is way below its critical micelle concentration (CMC). © 1995 John Wiley & Sons, Inc.     

Kinetics and mechanism of emulsion copolymerization. IV. Kinetic modeling of emulsion copolymerization of styrene and methyl methacrylate

Based on the micellar nucleation theory, a mathematical kinetic model for an unseeded emulsion copolymerization system is developed, where the radicals with and without electric charge are discriminated from each other in view of the role in the particle nucleation process. In order to demonstrate the validity and utility of this kinetic model, the experiments of the unseeded emulsion copolymerization of styrene (ST) and methyl methacrylate (MMA) are carried out varying the initial initiator (potassium persulfate) and emulsifier (sodium lauryl sulfate) concentrations and the monomer composition in the initial monomer feed, and various kinetic features observed are compared with the model predictions. It is concluded from this comparison that in this system, almost all the polymer particles are generated by the charged radicals stemming from the initiator, and further that this mathematical kinetic model can provide a satisfactory explanation of the various kinetic features observed.     

Tuning the particle size and charge density of the crosslinked polystyrene particles

We report the synthesis of charged spherical colloidal particles of poly [styrene‐(co‐2‐propene sulfonic acid)] crosslinked with divinylbenzene by emulsion polymerization. The effects of concentration of both the emulsifier and initiator on the polymerization, particle size, and charge density are studied. The particle size is found to be dependent on both the emulsifier and initiator concentration and their power dependencies are different. Below critical micelle concentration (CMC), the particle size varies significantly within a small range of emulsifier concentration. In contrast, particle size decrease is not very pronounced at the heterogeneous (micellar) particle nucleation regime where the emulsifier concentration is well above of the CMC. The power dependencies of the number of particles on surfactant concentration are explained in the light of conversion–time profile of the polymerization. The surface charge density of the colloidal particles also varies with both the emulsifier and initiator concentration. Both the particle size and charge density show an inverse relation with the molecular weight of the polymer. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Winsor I-like (micro)emulsion polymerization of styrene initiated by oil-soluble initiator

Batch emulsion polymerization of styrene initiated by an oil-soluble initiator and stabilized by non-ionic emulsifier (Tween 20) has been investigated. The rate of polymerization vs. conversion curve shows the two non-stationary rate intervals typical for the non-stationary-state polymerization. This behavior is a result of the continuous particle nucleation and the decrease of monomer concentration at the reaction loci with increasing conversion. The initial increase of the polymerization rate is attributed to the increase of particle number and the polymerization proceeding under the monomer-saturated condition—the Winsor I-like (micro)emulsion polymerization. The decrease of the polymerization rate is the result of the depressed transfer of monomer from the monomer reservoir to the reaction loci. Above 50 °C the monomer emulsion separates into two phases: the upper transparent monomer phase and the lower blue colored (microemulsion) phase. The polymerization mixture consists of the microdroplets (act as the reaction loci) and large degradable monomer droplets (act as the reservoir monomer and emulsifier). The continuous release of emulsifier from the monomer phase and the microdroplets induce the continuous particle nucleation up to high conversion. The initial formation of large particles results from the agglomeration of unstable growing particles and monomer droplets. The size of large (highly monomer-swollen) particles decreases with conversion and they merge with the growing particles at ca. 40-50% conversion. The coarse initial emulsion transformed during polymerization to the fine (semitransparent) polymer emulsion as a result of the continuous particle nucleation, the shrinking of highly monomer-swollen polymer particles and the depletion of monomer droplets. The low overall activation energy of polymerization is mainly ascribed to the decreased barrier for entering radicals into the latex particles with increasing temperature.     

Particle nucleation mechanism for the emulsion polymerization of styrene with a novel polyester emulsifier

The particle nucleation mechanism in emulsion polymerization of styrene with a novel polyester emulsifier, 5‐sulfoisophthalic acid dimethyl ester sodium salt‐modified tetracarboxylic acid‐terminated polyester (SMTAPE), was investigated. The consumption of SMTAPE micelles was monitored by the measurement of surface tension during the emulsion polymerization. Kinetic studies and emulsifier consumption clearly showed that a continuous nucleation mechanism without Smith–Ewart interval II was characteristic of this system. It was attributed to the high concentration of SMTAPE emulsifier in the polymerization, which led to a large surface area and a vast number of micelles around 10 nm in size that served as the major locus of particle nucleation. A broad particle size distribution was observed throughout the reaction, and the nucleation period lasted well into the reaction until the disappearance of the micelles or the disappearance of monomer droplets. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 82: 1061–1070, 2001     

Synthesis of well‐defined,functionalized polymer latex particles through semicontinuous emulsion polymerization processes

The design of a semicontinuous emulsion polymerization process, primarily based on theoretical calculations, has been carried out with the objective of achieving overall independent control over the latex particle size, the monodispersity in the particle size distribution, the homogeneous copolymer composition, the concentration of functional groups (e.g., carboxyl groups), and the glass‐transition temperature with n‐butyl methacrylate/n‐butyl acrylate/methacrylic acid as a model system. The surfactant coverage on the latex particles is very important for maintaining a constant particle number throughout the feed process, and this results in the formation of monodisperse latex particles. A model has been set up to calculate the surfactant coverage from the monomer feed rate, surfactant feed rate, desired solid content, and particle size. This model also leads to an equation correlating the polymerization rate to the instantaneous conversion of the monomer or comonomer mixture. This equation can be used to determine the maximum polymerization rate, only below or at which monomer‐starved conditions can be achieved. The maximum polymerization rate provides guidance for selecting the monomer feed rate in the semicontinuous emulsion polymerization process. The glass‐transition temperature of the resulting carboxylated poly(n‐butyl methacrylate‐co‐n‐butyl acrylate) copolymer can be adjusted through variations in the compositions of the copolymers with the linear Pochan equation. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 30–41, 2003     

Seeded emulsion polymerization of n-butyl acrylate utilizing miniemulsions

Nucleation of polymer particles in the seeded emulsion polymerization of n-butyl acrylate (BuA) was studied through experiments designed to control the amount of new particles formed. The results show that for the batch and semicontinuous seeded polymerization of BuA, a small amount of new particles was formed in the system in which the monomer was added neat, whereas a singificant amount of new particles was formed when the monomer was added as a miniemulsion. This suggests that new particles formed in the miniemulsion process were from nucleation of the monomer droplets. These experiments also showed that monomer-droplet nucleation decreased with increasing seed concentration in the reactor. For the seeded semicontinuous polymerizations, monomer-droplet nucleation decreases with decreasing BuA miniemulsion feed rate. The results also show that monomerdroplet nucleation takes place whenever miniemulsion droplets exist in the reactor. This study suggests that miniemulsions can be used to control the particle size distribution of a polymer latex system.     

Stability of carboxylated poly(butyl acrylate) latices during semibatch emulsion polymerization

The stability of latex particles in the semibatch emulsion polymerization of butyl acrylate (BA) in the presence of 0–10% acrylic acid (AA) was investigated. The amount of coagulum (i.e., large flocs caused by intensive coagulation) can be greatly reduced by an increase in the concentration of sodium lauryl sulfate (SLS) in the monomer emulsion feed. On the other hand, increasing the concentration of SLS in the initial reactor charge can result in an increase in the percentage of the particle volume change (i.e., a measure of the degree of limited flocculation) later in the process. Both the scrap and percentage of the particle volume change increase with an increase in the electrolyte concentration. Both the coagulation and secondary nucleation process can result in a significant deviation from the Novak model. Experimental data also show that latex particles comprising pure BA can lose their stability rapidly at higher total solids content because of the crowding effect. Incorporation of only 5% AA into the emulsion polymers greatly improves the latex stability. © 1996 John Wiley & Sons, Inc.     

Semibatch styrene suspension polymerization processes

Emulsion and suspension polymerization processes have widely been studied for more than 40 years. Although both polymerization processes are performed in heterogeneous media, each one presents its own typical characteristics, such as the particle size distribution, molecular weight distribution, polymer particle nucleation rate, and polymerization rate. In this study, semibatch styrene suspension polymerizations were carried out with feed compositions typical of emulsion processes. The initial reactor charge resembled the recipe of standard styrene suspension polymerizations, and the emulsion polymerization constituents were added during the batch. The influence of the moment at which the emulsion feed was started on the course of the polymerization and the effects of the feed on the polymer properties were analyzed. The polymer particle morphology and the average molecular weights changed very significantly with the emulsion feed time, and the changes could lead to the production of broad molecular weight distributions. Core–shell polymer particles could also be obtained, with the core being formed of polymer particles originating from the suspension polymerization process and the shell being formed of polymer particles originating from the emulsion polymerization. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 89: 3021–3038, 2003     

High solids content emulsions. III. Synthesis of concentrated latices by classic emulsion polymerization

Two different methods of producing bi‐ and trimodal latices of a mixture of methyl methacrylate, butyl acrylate, and small amounts of acrylic acid were tested. It is shown that a combination of concentrating blends of seed particles by semibatch reaction, followed by a nucleation of small particles plus a second semibatch phase allowed us to obtain stable latices with solids contents over 65% and viscosities of below 2500 mPa s^?1 with little coagulum formation. The key parameter in determining latex stability, coagulum formation, and viscosity appears to be the the particle size distribution, and especially its modification attributed to secondary nucleation. Because it is not possible to eliminate water‐soluble monomers from the polymerization recipe, secondary (homogeneous) nucleation must be minimized by careful addition of the free‐radical initiator and choice of monomer feed flow rates. The nucleation of the third population in the trimodal latices is best accomplished with a mixed surfactant system because renucleation by anionic surfactant alone leads to detrimental changes in the particle size distribution (PSD) resulting from excessive flocculation of particles. In addition, it was found that the viscosity of the final products was not sensitive to small changes in the ionic strength of the latex, although neutralization to a pH of 6 effectively doubles the final latex viscosity. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 1916–1934, 2002; DOI 10.1002/app.10513     

Transitional emulsion polymerisation: Zero-one to pseudo-bulk

The transitional behaviours of emulsion polymerisation for styrene and butyl acrylate (BA) monomers from zero-one to pseudo-bulk regime were mechanistically investigated. A dynamic mathematical model, which incorporates cross-over mechanism from zero-one to pseudo-bulk kinetics was developed for emulsion polymerisation and compared with experimental data for conversion, particle size and molar mass. Particles smaller than cross-over size follow zero-one kinetics and particles greater than cross-over size, they follow pseudo-bulk kinetics. In our mechanistic approach, particles nucleated from micelles, grow until the cross-over size is attained, based on zero-one kinetics, and subsequently continue to grow based on pseudo-bulk kinetics. Key findings from our work are that the developed transitional model predictions agree reasonably with experimental data on process and product attributes such as conversion, average molecular weight, molecular weight distribution (MWD), average particle size and particle size distribution (PSD). Optimal strategies for semibatch operation was developed using reaction temperature and monomer feed rate as process variables with specified initial conditions.     

Some factors affecting the particle growth in semicontinuous emulsion polymerization of acrylic monomers

Semicontinous emulsion polymerization of ethyl acrylate/ethyleneglycol dimethacrylate (90/10) and butyl acrylate/ethyleneglycol dimethacrylate (90/10) was studied. In the process a monomer emulsion feed was used, and the particle growth and the particle flocculation were found to be a competitive process. This was affected by distribution of water phase as well as by the distribution of emulsifier between the initial reactor charge and the emulsion of monomers. Several periods of particle generation were found during the process. The extent of particle flocculation was strongly affected by electrolyte concentration in the system and by copolymerization of acid groups containing comonomers.