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     

Polymer chain extension in semibatch emulsion polymerization with RAFT‐based transfer agent: The influence of reaction conditions on polymerization rate and product properties

A mathematical model was developed for batch and semiemulsion polymerizations of styrene in the presence of a xanthate‐based RAFT agent. Zero–one kinetics was employed along with population balance equations to predict monomer conversion, molecular weight (MWD), and particle size (PSD) distributions in the presence of xanthate‐based RAFT agents. The effects of the transfer agent (AR), surfactant, initiator, and temperature were investigated. Monomer conversion, MWD, and PSD were found to be strongly affected by monomer feed rate. The polymerization rate (Rp), number average molecular weight (Mn) and particle size (r) decreased with increasing AR. With increases in surfactant and initiator concentrations Rp increased, whereas with increase in temperature Mn decreased, Rp increased and r increased. In semibatch mode, Mn and r increased with increase in monomer flow rate. By feeding the RAFT agent along with the monomer (F_M/F_AR = N_Mo/N_ARo = 100), Mn attained a constant value proportional to monomer/RAFT molar ratio. The observed retardation in polymerization and growth rates is due to the exit and re‐entry of small radicals. Thus, chain extension was successfully achieved in semibatch mode. The simulations compared well with our experimental data, and the model was able to accurately predict monomer conversion, Mn, MWD, and PSD of polymer products. Our simulations and experimental results show that monomer feed rate is suitable for controlling the PSD, and the initial concentration and the feed rate of AR for controlling the MWD and PSD. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

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     

Dispersion polymerization of <Emphasis Type="Italic">N</Emphasis>-vinyl caprolactam in supercritical carbon dioxide

Dispersion polymerization of N-vinyl caprolactam (NVCL) was carried out in supercritical carbon dioxide (scCO₂) using three surfactants. The polymerization was performed in the presence of fluorine-based poly(heptadecafluorodecyl acrylate) (PHDFDA), poly(heptadecafluorodecyl methacrylate) (PHDFDMA) or siloxane-based PDMS-g-pyrrolidonecarboxylic acid (Monasil PCA) as a surfactant. FE-SEM and image analyzer were used to characterize particle morphology, size, and size distribution. When fluorine-based surfactants were used, spherical PVCL particles were obtained. Using Monasil PCA resulted in agglomerated and irregular polymer particles. The effect of concentration of surfactants, initiators, and monomer, and reaction pressure on the particle morphology, average particle size and particle size distribution (PSD) was also investigated with fluorine-based surfactant, PHDFDA or PHDFDMA.     

Characterization of polystyrene latexes

Polystyrene latexes were prepared by emulsion polymerization. Styrene was used as monomer, potassium persulfate was the reaction initiator and sodium hydrogen carbonate was used as buffer. Surfactant may or may not be used. Three types of surfactant, ie sodium dodecylbenzene sulfonate (anionic), Triton X‐100 and Vulcastab LW (nonionic), and hexadecyltrimethyl ammonium bromide (cationic), were used. The prepared latexes were characterized according to concentration, density, pH, ionic strength, particle size, particle size distribution and surface charge. For prepared latexes with anionic surfactant, the effects of temperature, initiator concentration, surfactant concentration and amount of monomer on the latex size were investigated. Scanning electron microscopy was used as a tool for latex characterization. The results show that by increasing temperature, initiator and emulsifier concentration, the latex diameter decreases. However, size increases by increasing the amount of monomer. A potentiometric titration technique was employed for determination of surface charge. It was found that for all latexes, surface charge densities are in the same range. © 2000 Society of Chemical Industry     

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     

悬浮态乳液聚合条件对聚氯乙烯树脂颗粒特性的影响

Suspended emulsion polymerization of vinyl chloride was carried out in a 5 L autoclave. The influence of agitation, polymerization conversion, dispersant and surfactant on the average particle size (PS) and particle size distribution (PSD), particle morphology and porosity of polyvinyl chloride (PVC) resin was investigated. It showed that the agitator had great influence on the smooth operation of polymerization, PS and PSD. The PS increased and PSD became narrow as polymerization conversion became high. The porosity decreased with the increase of conversion. A convenient choice of additives, both dispersants and non-ionic surfactants, allows one to adjust PS and PSD. The PS decreased with the addition of polyvinyl alcohol or hydroxypropyl methylcellulose dispersants,and increased with the addition of Span surfactants. The addition of dispersants or surfactants also affected the morphology and porosity of resin, and PVC resin with looser agglomeration and homogeneous distribution of primary particles was prepared.     

On‐line acoustic attenuation spectroscopy of emulsions stabilized by vinyl alcohol–vinyl acetate copolymers: a model system for the suspension polymerization of vinyl chloride

BACKGROUND: Poly[(vinyl alcohol)‐co‐(vinyl acetate)] (PVA) copolymers obtained by partial hydrolysis of poly(vinyl acetate) are currently used as industrial stabilizers in the suspension polymerization of vinyl chloride monomer (VCM). Their molecular characteristics, mainly the average degree of hydrolysis (DH ) and average degree of polymerization (DPw ), have a major influence on the monomer droplet size and the properties of the final poly(vinyl chloride) resin. RESULTS: The average droplet size and size distribution of chlorobutane/water emulsions, as a model system for VCM/water emulsions, were studied using acoustic attenuation spectroscopy on‐line with an agitated laboratory reactor. The emulsions were stabilized by PVA with DH values between 73 and 88 mol% and DPw values between 450 and 2500. The effects of agitation speed, stirring time and concentration of the PVA copolymers were investigated. An attempt was made to correlate the interfacial tension and the droplet size. CONCLUSION: On‐line acoustic spectroscopy appears to be a suitable technique for the real‐time control of the droplet size of monomer suspensions. The advantages and limitations of the technique are outlined. The validity and the application limits of the commonly cited correlation between the droplet size and the Weber number are established for polymeric surfactant‐stabilized emulsions. Copyright © 2009 Society of Chemical Industry     

Polystyrene latex synthesized in presence of ultrasonic initiation

The low water solubility of styrene (St) monomer increase the need for a good initiator system to speed up the emulsion polymerization and remove unreacted monomers. Polymerization of styrene monomer in water was performed at 30, 50, and 70°C under ultrasonic irradiation using sodium dodecyl sulfate as surfactant and ammonium persulfate as initiator. Ultrasonic energy was used as a tool to speed up the polymerization. Combining ultrasonic and ammonium persulfate led to a higher conversion and higher rate of polymerization. Ultrasonic energy has an effect on the particle size distribution. The particle size distribution increases with an increase in the monomer conversion of styrene for ultrasonic polymerization, whereas the particle size distribution did not change with an increase in the monomer conversion compared with the conventional thermal polymerization results. Higher molecular weights were obtained under ultrasonic irradiation. FE‐SEM and TEM pictures show different morphology with changing temperature polymerization. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Suspended emulsion,a new process for vinyl chloride polymerization: Morphology control through surface active additives

Suspended emulsion is a new polymerization process in which a water phase containing the initiator is suspended in an organic phase containing the monomer; the polymer formed is insoluble in both the organic and water phase. The final morphology of the polymer is a powder of grains (around 100–300 microns) formed with agglomerates of primary particles (around 1 micron). This article describes the effects of small amounts of either suspending agents (water-soluble polymers) or surfactants. These effects concern mainly the morphology (grain and particle size), but also the polymerization kinetics. A rather homogeneous distribution of grains and particles inside the grain may be obtained by using a cellulosic polymer as the suspending agent and an anionic surfactant such as sodium dodecyl sulfate. © 1994 John Wiley & Sons, Inc.     

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     

Mass transfer and radical flux effects in dispersed‐phase polymerization of isooctyl acrylate

The kinetics of dispersed phase polymerization of a highly water‐insoluble monomer (isooctyl acrylate) were explored in emulsion, miniemulsion, and microsuspension polymerization. The effects of monomer water solubility and choice of initiator (oil‐ vs. water‐soluble) strongly impact the final product (particle size and molecular weight distribution). For emulsion polymerization, as the surfactant concentration was increased, there was a transition from homogenous to micellar nucleation near the CMC, then a drop in nucleation rate at high surfactant concentration due to insufficient radical flux to support more nucleation. For miniemulsion polymerization, a slow rate of growth of (droplet) nucleation with surfactant concentration was found, followed (at the CMC) by an increase in the rate of nucleation with added surfactant as the mode of nucleation switched to micellar. The conversion‐time kinetics of microsuspensions could be modeled with a bulk polymerization model. IOA is sufficiently insoluble in the aqueous phase that emulsion polymerization may or may not be reaction limited. The presence of a stabilizer such a PAA, the use of an oil‐soluble initiator such as BPO, and the insolubility of IOA in the aqueous phase all push the polymerization locus toward droplet (microsuspension) nucleation and bulk kinetics.© 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 5649–5666, 2006     

Strategies for the production of high solids acrylic/methacrylic core‐shell latices

Well‐defined poly(butyl acrylate)/poly(methyl methacrylate) (PBA/PMMA) core shell particles with a moderately high solid content (49%) and particle diameters of less than 200 nm were prepared via seeded emulsion polymerization with a redox initiator and an anionic surfactant. Low‐viscosity (less than 150 cps at 20 s^?1) latex products were obtained by controlling the particle size distribution to within certain limits. Polymerization conversion and kinetics were followed gravimetrically and were adjusted so as to obtain recipes that could be scaled‐up for industrial production. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

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     

Narrow size‐distribution poly(methyl methacrylate) nanoparticles made by semicontinuous heterophase polymerization

The effect of surfactant (sodium dodecyl sulfate) concentration on particle size, molar masses, glass transition, and tacticity of poly(methyl methacrylate) (PMMA) nanoparticles synthesized by semicontinuous heterophase polymerization under monomer‐starved condition at constant monomer feeding rate is reported. Starved conditions are confirmed by the low amount of residual monomer throughout the reaction and by the fact that the instantaneous polymerization rate is similar to the feeding rate of monomer. Under these conditions, polymer particles in the nanometer range (20–30 nm) were obtained with narrow size distribution (1.07 < D_w/D_n < 1.18), depending of surfactant concentration. Final particle size diminishes as the surfactant concentration is increased. Glass transition temperatures and syndiotactic content (54%–59%) of the produced polymers are substantially higher than those reported for commercial and bulk‐made PMMA. Molar masses are much lower than those expected from termination by chain transfer to monomer, which is the typical termination mechanism in 0–1 emulsion and microemulsion polymerization of this monomer. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

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     

High‐Solid‐Content Emulsions of PVC: Scale‐Down of an Industrial Process for Enhanced Understanding of Particle Formation Part 3: Production of Bimodal Latexes

A scale‐down study of an industrial reactor for the production of polyvinyl chloride (PVC) via an emulsion polymerization process was carried out in order to understand the cause of batch‐to‐batch variations in product quality. The results in Part 2 of this series of papers indicated that a large excess of base is required to control the particle size distribution (PSD) of the seed process. Here, it is demonstrated that the flow rate of the initiator and the second‐stage surfactant are the most important parameters for PSD control. Altering the time point at which the initiator and surfactant are injected allows controlling the relative volume fractions of large and small particles.     

Synthesis of poly(styrene‐co‐4‐vinylpyridine) microspheres via dispersion polymerization: Effect of the concentration of 4‐vinylpyridine

Amphiphilic copolymer microspheres of poly(styrene‐co‐4‐vinylpyridine) were prepared by dispersion polymerization in an alcohol/water medium. The synthesis of poly(styrene‐co‐4‐vinylpyridine) microparticles was successfully carried out, and the latexes had a spherical morphology with good monodispersity. The degree of conversion in the early stage of polymerization decreased with increasing 4‐vinylpyridine (4VP) monomer content, but the final conversions were similar (>95%). The copolymerization rate decreased with increasing 4VP content, and a broad particle size distribution was observed with 20 wt % 4VP because of the prolonged nucleation time. With the 4VP concentration increasing, the molecular weight of the copolymer microspheres decreased, and the glass‐transition temperature of the copolymers increased; this indicated that all the copolymers were random and homogeneous. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Role of anionic and nonionic surfactants on the control of particle size and latex colloidal stability in the seeded emulsion polymerization of butyl methacrylate

The evolution of the main colloidal parameters in the seeded starved‐feed semi‐continuous emulsion polymerization of butyl methacrylate (BMA) was investigated, with the main purpose of assessing the effectiveness of the semi‐empirical relationship S = K · S_S · ΔA/A_S as a tool to define the surfactant/monomer feed ratio (∝ K) best suited to achieve a target particle size. In particular, the effect of the type and amount of surfactant [i.e., anionic, sodium dodecyl sulfate (SDS), or nonionic, Brij 58P] added during the semi‐continuous stage was considered. Coagulum formation was never observed under the adopted experimental conditions. To detect the occurrence of secondary nucleation or particle aggregation, or both, the particle size and number of particles, the surface tension and the particle surface coverage ratio were correlated. The best results were obtained with SDS and 0.8 ≤ K ≤ 3. In fact, under the selected experimental conditions, only with SDS did the number of particles remain nearly constant throughout the polymerization at the value defined by the seed latex; the particle size distribution was highly monodisperse, and the final particle diameter closely matched the calculated one (～ 120 nm). The above semi‐empirical relationship based on the adjustable parameter K was validated by running test polymerizations aimed at lattices with well‐defined particle size. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 3083–3094, 2006     

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.