Crystal Growth in Drowning‐Out Crystallization using a T‐Mixer

The kinetics of nucleation and crystal growth in drowning‐out crystallization using a T‐mixer were estimated using crystal size distribution, taking into account a size‐independent growth. At the conditions of the feed compositions investigated, the product weight mean size changed from 7–29 μm when the residence time varied between 0.32 and 0.61 s. Nucleation and growth rates were expressed simply as a function of the residence time. The T‐mixer can be used to generate high levels of supersaturation due to inducing micro‐mixing effects. The particle size correlated well with the ratio of growth rate to nucleation rate. Finally, the particle size obtained in drowning‐out crystallization using a T‐mixer was found to be proportional to the 1.69^th power function of the residence time.     

Nonisothermal crystallization of highly‐filled polyolefin/calcium carbonate composites

Nonisothermal crystallization kinetics of highly‐filled polyolefin composites was studied by means of differential scanning calorimetry (DSC). Two types of commercial calcium carbonate based fillers (modified with stearic acid and nonmodified one) were used for our investigations. In order to evaluate the crystallization kinetics changes of composites, the Avrami theory modified by Jeziorny was used. Validity of mineral fillers modification with stearic acid has been proved by thermal analysis. Because of the suppression of the heterogeneous nucleation effect resulting from calcium carbonate with stearic acid modification, an increase in the processability of highly‐filled polyolefin cast films might occur. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 41201.     

Integrated B2B‐NMPC control strategy for batch/semibatch crystallization processes

The uncertainty in crystallization kinetics is of major concern in manufacturing processes, which can result in deterioration of most model‐based control strategies. In this study, uncertainties in crystallization kinetic parameters were characterized by Bayesian probability distributions. An integrated B2B‐NMPC control strategy was proposed to first update the kinetic parameters from batch to batch using a multiway partial least‐squares (MPLS) model, which described the variances of kinetic parameters from that of process variables and batch‐end product qualities. The process model with updated kinetic parameters was then incorporated into an NMPC design, the extended prediction self‐adaptive control (EPSAC), for online control of the final product qualities. Promising performance of the proposed integrated strategy was demonstrated in a simulated semibatch pH‐shift reactive crystallization process to handle major crystallization kinetic uncertainties of L‐glutamic acid, wherein smoother and faster convergences than the conventional B2B control were observed when process dynamics were shifted among three scenarios of kinetic uncertainties. © 2017 American Institute of Chemical Engineers AIChE J, 2017     

Crystallization behavior of “wet brush” and “dry brush” blends of PS‐b‐PEO‐b‐PS/h‐PEO

The crystallization behavior of the blending system consists of homopolymer poly(ethylene oxide) (h‐PEO) with different molecular weights, and polystyrene‐block‐poly (ethylene oxide)‐block‐polystyrene (PS‐b‐PEO‐b‐PS) triblock copolymer has been investigated by DSC measurements. The crystallization of PEO block (b‐PEO) in block copolymer occurs under much lower temperature than that of the h‐PEO in the bulk (ΔT > 65 °C), which is attributed to the homogeneous nucleation crystallization behavior of the b‐PEO microdomains. In both the “dry‐brush” and the “wet brush” blending systems, the homogeneous nucleation crystallization temperature of PS‐b‐PEO‐b‐PS/h‐PEO blends increases due to the increase of the domain size. The heterogeneous nucleation crystallization temperatures of h‐PEO in the wet brush blending systems are higher than that of the corresponding h‐PEO in the bulk. At the same time, the heterogeneous nucleation crystallization temperature of b‐PEO10000 decreases from 43°C to 30°C and 40°C in the h‐PEO600 and h‐PEO2000 blending systems, respectively, because of the stretching of the PEO chains in the wet brush. However, this kind of phenomenon does not happen in the dry brush blending systems. The self‐seeding procedure was used to further ascertain the nucleation mechanism in the crystallization process. As a result, the self‐seeding domains have been confirmed, and the difference between the dry brush and wet brush systems has been observed. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Layer double hydroxides for enhanced poly(3‐hydroxybutyrate‐co‐3‐hydroxyvalerate) crystallization

Enabling the widespread utilization of poly[(3‐hydroxybutyrate)‐co‐(3‐hydroxyvalerate)] (PHBV) is strongly associated with enhancing its crystallization kinetics. In this article, we utilize a highly surface active (one reactive group per nanometer square) anion exchanged layered‐double hydroxide (LDH) functionalized by stearic acid to probe the crystallization kinetics of PHBV. Our prior work has shown that the addition of LDH decreases the cold crystallization and induces a melt recrystallization peak in PHBV. Since the melt‐recrystallization temperature shifted to higher temperature and its corresponding enthalpy increased with increasing LDH loading, this article is focused on understanding the effect of LDH on kinetics and energetics of PHBV crystallization. Both Avrami and Lauritzen–Hoffman modeling are utilized to develop a comprehensive understanding of thermal history effects through differential scanning calorimetry and polarized optical microscopy measurements. Five concentrations by weight of LDH are used: 1, 3, 5, and 7%. The results show that the addition of LDH promoted both primary and secondary nucleation at low concentrations but additional LDH resulted in primary nucleation alone. The crystallization rate and activation energy show a significant increase, which is accompanied by a decrease in the nucleation constant, the surface energy and the work of chain folding for PHBV crystallization. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2013     

Modeling of bubble‐size distribution in water and freon co‐blown free rise polyurethane foams

A model has been developed to simulate the foam characteristics obtained, when chemical (water) and physical (Freon) blowing agents are used together for the formation of polyurethane foams. The model considers the rate of reaction, the consequent rise in temperature of the reaction mixture, nucleation of bubbles, and mass transfer of CO₂ and Freon to them till the time of gelation. The model is able to explain the experimental results available in literature. It further predicts that the nucleation period gets reduced with increase in water (at constant Freon content), whereas with increase in Freon (at constant water) concentration nucleation period decreases marginally leading to narrower bubble‐size distribution. By the use of uniform sized nuclei added initially, the model predicts that the bubble‐size distribution can be made independent of the rate of homogeneous nucleation and can, thus, offer an extra parameter for its control. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40745.     

Effect of 1,3,5‐trialkyl‐benzenetricarboxylamide on the crystallization of poly(lactic acid)

A series of 1,3,5‐trialkyl‐benzenetricarboxylamides (BTA‐Rs) with different side‐chain lengths of n‐alkyl are synthesized to use as nucleating agents of poly (lactic acid) (PLA). Crystallization rate of PLA is detailed discussed in nonisothermal melt‐crystallization with addition of the synthesized nucleating agents. Among these BTA‐Rs, BTA‐n‐butyl (BTA‐nBu) shows the most excellent nucleation ability for PLA. The influences of BTA‐nBu on the nonisothermal melt‐crystallization and cold‐crystallization from the glassy state, isothermal crystallization, crystalline structure, and spherulite morphology of PLA are investigated. It is found that 0.8 wt % is the optimal weight fraction of BTA‐nBu to improve the crystallization of PLA. In the case of isothermal melt‐crystallization from melt, the addition of BTA‐nBu shortens the crystallization half‐time and speeds up the crystallization rate of PLA with no discernible effect on the crystalline structure. Besides, BTA‐nBu nucleated PLA exhibits smaller spherulites size and larger nucleation density than that of pure PLA. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 130: 1328‐1336, 2013     

Nucleation and Supersaturation in Drowning‐Out Crystallization using a T‐Mixer

In order to assess the performance of drowning‐out crystallization using a T‐mixer, nucleation and supersaturation were studied. The particle size was changed considerably with the solvent fraction and the feed rate, which were the main parameters controlling the supersaturation. At S = 1.7, the boundary point between homogeneous and heterogeneous nucleations was found from a log‐log plot of supersaturation rate versus maximum supersaturation. Drowning‐out crystallization using a T‐mixer could easily generate high supersaturations of up to 50, which were adjusted by the feed rate and the ratio of solvent to antisolvent. Nano‐ and micron‐sized particles can be prepared by drowning‐out crystallization using a T‐mixer.     

Poly(styrene‐co‐maleic anhydride) ionomers as nucleating agent on the crystallization behavior of poly(ethylene terephthalate)

Poly(styrene‐co‐maleic anhydride) (SMA) ionomers were synthesized and designed as a new kind of nucleation agent according to the crystallization theory for improving the crystallization of poly(ethylene terephthalate) (PET). The crystallization behavior of PET with the addition of nucleation agents was investigated by differential scanning calorimetry, polarized‐light microscope, and X‐ray diffraction (XRD). Avrami equation and Hoffman–Lauritzen theory are adopted for analyzing isothermal and non‐isothermal crystallization kinetics, respectively. The results show that the addition of 1 wt % SMA ionomers effectively accelerates the crystallization rate and reduces the fold surface free energy of PET at high temperature regions. PLM results also indicated that the crystals impinge on each other, thus decreasing the spherulite size for PET/SMA ionomers samples compared with PET. XRD measurement revealed that the introduction of SMA ionomers does not change the crystal structure but indeed accelerates the crystallinity of PET. The results clearly demonstrate that our synthesized SMA ionomers are an efficient nucleating agent for PET. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41240.     

Polylactide/nano‐ and micro‐scale silica composite films. II. Melting behavior and cold crystallization

Nonisothermal crystallization of polylactide (PLA)/silica composites prepared by (i) directly blending the PLA with nanoscale colloidal silica sol and by (ii) a sol–gel process are studied by differential scanning calorimeter (DSC) at various heating rates. Samples quenched from the molten state exhibited two melting endotherms (T_ml and T_mh) due to melt‐recrystallization during the DSC scans. Lower heating rate and the presence of silica particles generate a lower peak intensity ratio of T_ml /T_mh. The nonisothermal crystallization kinetics is analyzed by modified Avrami model, Ozawa model, and Liu‐Mo models. The modified Avrami and Liu‐Mo models successfully described the nonisothermal cold crystallization processes, but Ozawa is inapplicable. The nucleation constant (K_g) is calculated by modified Lauritzen‐Hoffman equation and the activation energy by Augis‐Bennett, Kissinger, and Takhor models. These calculated parameters indicate consistently that the nanoscale silica particles seem to form more heterogeneous nucleation to increase crystallization, but microscale one form hindrance to retard crystallization. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Synergistic effects of N,N′‐bis (benzoyl) sebacic acid dihydrazide and talc on the physical and mechanical behaviors of poly(l‐latic acid)

The important practical problem of poor heat stability of poly(l ‐lactic acid) (PLLA) is addressed by the addition of N, N′‐bis (benzoyl) sebacic acid dihydrazide (BSAD) and talc as a nucleating agent system. The idea of incorporating talc into the PLLA/BSAD composites is that talc can provide supplementary nucleation effect with very small amount of BSAD (0.2 wt %) and therefore can improve the heat deflection resistance of PLLA materials. Effects of BSAD/talc on morphology, crystallization behavior, heat resistance, and mechanical properties of PLLA/BSAD/talc were investigated after annealing processes. The results indicated that the BSAD/talc system increased the crystallinity from 6.0% of pure PLLA to a maximum 42.9% by the synergistic effects of BSAD and talc increasing the growth of spherulites and nucleation density, respectively. After annealing at different temperatures, the heat deflection temperature (HDT) of PLLA was improved dramatically due to synergistic effects of BSAD/talc between restricted chain movement and acceleration of crystallization. At high temperature (above T_g), the thermo‐mechanical properties of PLLA is mainly determined by the crystallinity and the reinforcement effect of talc acted as a filler. Moreover, effects of BSAD/talc on mechanical properties were discussed. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41454.     

Crystallization kinetics of poly(3‐hydroxybutyrate‐co‐3‐hydroxyvalerate)/clay nanocomposites

The preparation and properties of nanocomposites, consisting of a poly(3‐Hydroxybutyrate‐co‐3‐hydroxyvalerate) and an organophilic clay are described. The effect of organophilic clay on the crystallization behavior of (PHBV) was studied. A differential scanning calorimeter (DSC) was used to monitor the energy of the crystallization process from the melt. During the crystallization process from the melt, the organophilic clay led to an increase in crystallization temperature (T_c) of PHBV compared with that for plain PHBV. During isothermal crystallization, dependence of the relative degree of crystallization on time was described by the Avrami equation. The addition of organophilic clay caused an increase in the overall crystallization rate of PHBV, but did not influence the mechanism of nucleation, and growth of the PHBV crystals and the increase caused by a small quantity of clay is move effective than that large one. The equilibrium melting temperature of PHBV was determined as 186°C. Analysis of kinetic data according to nucleation theories showed that the increase in crystallization rate of PHBV in the composite is due to the decrease in surface energy of the extremity surface. The mechanical test shows that the tensile strength of hybrid increased to 35.6 MPa, which is about 32% higher than that of the original PHBV with the incorporation of 3 wt % clay, and the tensile modulus was also increased. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 93: 655–661, 2004     

Isothermal crystallization kinetics and melting behaviors of poly(butylene terephthalate) and poly(butylene terephthalate‐co‐fumarate) copolymer

The isothermal crystallization kinetics and melting behaviors after isothermal crystallization of poly(butylene terephthalate) (PBT) and poly(butylene terephthalate‐co‐fumarate) (PBTF) containing 95/5, 90/10, and 80/20 molar ratios of terephthalic acid/fumaric acid were investigated by differential scanning calorimetry. The equilibrium melting temperatures of these polymers were estimated by Hoffman–Weeks equation. So far as the crystallization kinetics was concerned, the Avrami equation was applied and the values of the exponent n for all these polymers are in the range of 2.50–2.96, indicating that the addition of fumarate does not affect the geometric dimension of PBT crystal growth. Crystallization activation energy (ΔE) and nucleation constant (K_g) of PBTF copolymers are higher than that of PBT homopolymer, suggesting that the introduction of fumarate hinders the crystallization of PBT in PBTF. POLYM. ENG. SCI., 2013. © 2012 Society of Plastics Engineers     

Crystallization behavior of spray‐dried and freeze‐dried graphene oxide/poly(trimethylene terephthalate) composites

Two types of graphene oxide (GO) powders were prepared by freeze‐drying or spray‐drying method, and their composites with poly(trimethylene terephthalate) (PTT) were prepared by melt blending. The influence of GO powders' type and content on crystallization behavior of PTT was investigated by differential scanning calorimeter (DSC) and polarized optical microscopy (POM). DSC results indicated that the overall crystallization rate of PTT was accelerated by well‐dispersed GO material which acts as a heterogeneous nucleation agent, since the Avrami parameter obtained is near 3. On the contrary, large GO aggregates which is in the minority will hinder the nucleation. Interestingly, large and well‐defined PTT spherulites instead of tremendous stunted spherulites were observed from POM, which means only a small portion of GO powders was acted as nucleation agent. Meanwhile, GO powders had no effect on PTT spherulites growth rate. In addition, the band spacing of PTT spherulites became weaker and wider with increasing GO content. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40332.     

Crystallization and melting behavior of nano‐CaCO3/polypropylene composites modified by acrylic acid

Nano‐CaCO₃/polypropylene (PP) composites modified with polypropylene grafted with acrylic acid (PP‐g‐AA) or acrylic acid with and without dicumyl peroxide (DCP) were prepared by a twin‐screw extruder. The crystallization and melting behavior of PP in the composites were investigated by DSC. The experimental results showed that the crystallization temperature of PP in the composites increased with increasing nano‐CaCO₃ content. Addition of PP‐g‐AA further increased the crystallization temperatures of PP in the composites. It is suggested that PP‐g‐AA could improve the nucleation effect of nano‐CaCO₃. However, the improvement in the nucleation effect of nano‐CaCO₃ would be saturated when the PP‐g‐AA content of 5 phf (parts per hundred based on weight of filler) was used. The increase in the crystallization temperature of PP was observed by adding AA into the composites and the crystallization temperature of the composites increased with increasing AA content. It is suggested that the AA reacted with nano‐CaCO₃ and the formation of Ca(AA)₂ promoted the nucleation of PP. In the presence of DCP, the increment of the AA content had no significant influence on the crystallization temperature of PP in the composites. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 91: 2443–2453, 2004     

Crystallization and melting behavior of homogeneous and heterogeneous linear low‐density polyethylene resins

The crystallization behavior of homogeneous and heterogeneous linear low‐density polyethylenes (LLDPE) was investigated by evaluating the characteristics of melting traces obtained by differential scanning calorimetry (DSC). Based on the isothermal experimental results, the concept of the effective nucleation induction time is suggested. In the initial crystallization stage, the Avrami equation in conjunction with the effective induction time can be used to successfully describe the overall crystallization kinetics. Avrami exponents 2, 1.5, and 1 were found to apply in regimes III, II, and IM, respectively, as identified by the modified Hoffman‐Lauritzen (MHL) equation. The kinetic parameters estimated from evaluating the linear crystallization behavior during spherulitic growth experiments using polarized light microscopy (PLM) are in agreement with the overall crystallization kinetic parameters obtained from DSC experiments. POLYM. ENG. SCI., 45:1140–1151, 2005. © 2005 Society of Plastics Engineers     

Polymer crystallization kinetics,master quotients,master curves and Nakamura‐Ozawa‐equations of iPP and PTFE

Evaluation concepts related to Avrami master curves are described for the analysis of isothermal and non‐isothermal kinetic processes exhibiting topological nucleation and growth characteristics. These evaluation concepts are shown to be helpful for studies focusing on kinetic data of polymer crystallization experiments with iPP (isotactic polypropylene) and PTFE (polytetrafluoroethylene). An apparent m‐order reaction model is discussed with respect to the isokinetic nucleation and growth model of Nakamura as well as to the non‐isothermal crystallization kinetics theory of Ozawa. Thus, the cooling functions χ(T) of iPP and PTFE, obtained by analyzing DSC (differential scanning calorimetry) experiments with constant cooling rates, are calculated in two alternative ways by using clearly different mathematical approaches. Finally, master quotients, theoretical crystallization limits, and further types of master curves are defined. Polym. Eng. Sci. 44:2194–2202, 2004. © 2004 Society of Plastics Engineers.     

Critical seed loading from nucleation kinetics

A method is presented for preparing critical seed loading diagrams for nonaggregating systems knowing only the nucleation kinetics. This is advantageous because it is much less time‐consuming than developing and solving a complete batch process model including solubility expressions and growth rate kinetics. Furthermore, there are many more reports available in the literature of nucleation kinetics alone than there are of complete batch crystallization process models, because expressions for the nucleation rate as a function of crystal growth rate can be rapidly determined from mixed‐suspension, mixed‐product‐removal (MSMPR) data without measuring the supersaturation. The results for 43 systems show that there is a great deal of variability in the critical seed loading, and a single correlation is inadequate to describe the relationship between critical seed loading and seed size. For a seed size of 10 µ, seed loading can effectively suppress nucleation in 92% of cases, while for seeds of size 50, 100, and 200 µ, seed loading can suppress nucleation in 74, 61, and 39% of cases, respectively. © 2014 American Institute of Chemical Engineers AIChE J, 60: 1645–1653, 2014     

Influence of dispersed organophilic montmorillonite at nanometer‐scale on crystallization of poly(L‐lactide)

We investigated the effects of surface‐treated organophilic clay on the crystallization of poly(L ‐lactide) (PLLA) in their hybrids. The natural nano‐clay in PLLA/clay hybrids acts as a heterogeneous nucleating agent to facilitate crystallization. On the contrary, extensive distributions of induction periods for nucleation are observed in the individual spherulites of neat PLLA and PLLA/organophilic clay hybrids. Therefore, it is suggested that nucleation type of neat PLLA and PLLA/organophilic clay hybrids implies nearly growth geometry as a homogeneous one. Further, under the presence of nano‐clay in their composites, PLLA matrix form the orthorhombic lattice structure corresponded to the α‐form crystal. Since this experimental fact implies little effect of the clay particles on polymorphism of PLLA crystal, the nucleating effect of the organophilic clay seems weaker than the natural clay itself. However, an increase in clay content enhances the growth rates of spherulite for hybrids. Consequently, most of hybrids exhibit an increase in overall crystallization rates at any crystallization temperature in spite of relatively lower nucleation rate of PLLA crystallites itself. In addition, the Avrami exponents (n) obtained by relatively low crystallization temperature ranged from 4 to 6, implying that the growth geometry was dominated sheaf‐like structure in early stage of isothermal crystallization. POLYM. ENG. SCI., 2008. © 2008 Society of Plastics Engineers     

Effect of orotic acid as a nucleating agent on the crystallization of bacterial poly(3‐hydroxybutyrate‐co‐3‐hydroxyhexanoate) copolymers

The kinetics of crystallization induced by orotic acid (OA) and boron nitride (BN) as nucleating agents were investigated for bacterial poly(3‐hydroxybutyrate‐co‐3‐hydroxyhexanoate)s (P(HB‐co‐HH)s) containing from 0 to 18% HH monomer units. The nucleation efficiency of these two chemicals was investigated by differential scanning calorimetry (DSC) and polarized optical microscopy (POM). It was found that both orotic acid and boron nitride are able to nucleate the crystallization of PHB. In the case of P(HB‐co‐HH) copolymers, orotic acid showed an outstanding nucleating effect. The comparison of half‐crystallization times shows that for P(HB‐co‐10% HH), the crystallization initiated by orotic acid is more than three time faster than the one induced by boron nitride (t_1/2BN/t_1/2OA(60°C) = 3.7 and t_1/2BN/t_1/2OA(90°C) = 4.5). According to the fact that orotic acid is a biodegradable, biocompatible and a nontoxic chemical, this nucleating agent is a promising solution for PHAs used in medical applications such as implants. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009