Near infrared (NIR) spectroscopy for in-line monitoring of polymer extrusion processes

In recent years, near infrared (NIR) spectroscopy has become an analytical tool frequently used in many chemical production processes. In particular, on-line measurements are of interest to increase process stability and to document constant product quality. Application to polymer processing e.g. polymer extrusion, could even increase product quality. Interesting parameters are composition of the processed polymer, moisture, or reaction status in reactive extrusion. For this issue a transmission sensor was developed for application of NIR spectroscopy to extrusion processes. This sensor includes fibre optic probes and a measuring cell to be adapted to various extruders for in-line measurements. In contrast to infrared sensors, it only uses optical quartz components. Extrusion processes at temperatures up to 300 degrees C and pressures up to 37 MPa have been investigated. Application of multivariate data analysis (e.g. partial least squares, PLS) demonstrated the performance of the system with respect to process monitoring: in the case of polymer blending, deviations between predicted and actual polymer composition were quite low (in the range of +/-0.25%). So the complete system is suitable for harsh industrial environments and could lead to improved polymer extrusion processes.     

The role of analytical chemistry in process quality control

The growing need for quality supervision and control in production processes is briefly outlined. After a summary of available process analytical devices, and a short discussion of their possibilities and limitations, an alternative approach is discussed. This approach is based on the development of a dynamic process model which allows on-line quality predictions to be made by means of so- called state estimators. The advantage is that it becomes possible to use quantities which give only indirect information about the product quality, but which are more readily accessible for continuous or on-line monitoring in earlier stages of the process.     

Device for non-disruptive taking of melt samples from a compounding process and direct injection molding

A concept for taking a sample from a polymer melt stream plus the direct processing of this melt to specimen is presented. Therefore, a melt sampling and direct injection molding (MSIM) device was developed. Process parameters were studied and the set-up was implemented successfully. Using the MSIM device, different thermoplastics were processed and provided specimen characterized. The mechanical material properties from samples of the MSIM process show a good consistency compared with data from conventional processes. The MSIM device can be used in production processes for quality control, e.g. color or mechanical properties, as well as in the field of research and development to reduce development cycles.     

Microphotometric Detection of Particles/Inhomogeneities in Flowing Polymer Melts

By application of different unique microphotometric sensors it is possible to detect and quantify disturbing particles (gels, unmolten resins, black spots, additive agglomerates, bubbles) within a flowing polymer melt in realtime during extrusion processing. These particles result in disadvantageous optical and mechanical properties of a final polymer product. Sensors can be adapted inline and online to different extruders at various positions. This seems to give technical and economic benefit to quality control and process optimisation in polymer processing.     

Steady State Simulation of Ethylene Polymerization Using Multiple-Site Coordination Catalysts

Summary: Simulation models are important tools for the development and optimization of polymerization processes because they can describe catalyst performance and polymer properties as a function of polymerization kinetics and process conditions. As the polyolefin industry moves towards the production of resins with more complex microstructures, these models become essential for process understanding and product design. A simulation model has been developed for the polymerization of ethylene in a process with n reactors working in series. The model can predict raw material conversions and product properties like the molecular weight distribution (MWD) coupled with short chain branching distribution (SCBD), melt index, density and fluff morphology. Model parameters have been obtained from laboratory data. The model predictions are in good agreement with experimental results.     

小口罩博物馆奇遇记

Masks have played an important role in the fight against COVID-19. This paper introduces the knowledge of melt blown fabric and non-woven fabric related to mask by means of personification, and the relationship between melt index and product quality. Readers can understand the knowledge of polymer chemistry related to masks in interesting reading.     

Size-exclusion chromatography with on-line ultraviolet, proton nuclear magnetic resonance and mass spectrometric detection and on-line collection for off-line Fourier transform infrared spectroscopy.

The coupling of HPLC with UV detection and on-line NMR spectroscopy and mass spectrometry combined with a dedicated interface for the collection of the chromatographic eluent for subsequent Fourier transform (FT) IR has been investigated using a number of polymer additives as model compounds. Size-exclusion chromatography was performed using deuterated chloroform as eluent with the separation monitored on-line by UV detection at 254 nm and on-flow 1H-NMR and MS. The effluent from the NMR probe was directed to a dedicated HPLC interface where it was deposited on a germanium plate for subsequent FT-IR. NMR and MS spectra were successfully obtained for 2,6-di-tert.-butyl-4-methylphenol, octadecyl-3-(3,5-di-tert.-butyl-4-hydroxyphenyl) propionate (Irganox 1076) and diisooctyl phthalate on-line and FT-IR spectra for all three compounds were obtained off-line. Practical problems encountered with this multiple hyphenation are described.     

Application of Polyelectrolytic Temperature-Responsive Hydrogels in Chemical Sensors

Summary: A rapidly expanding field of on-line process monitoring and on-line control in biotechnology, food industry, pharmaceutical industry, process chemistry, environmental measuring technology, water treatment and sewage processing requires the development of new micro fabricated reliable chemical and biosensors that are specific for particular species and can attain the analytic information in a faster, simpler and cheaper manner. Using a functionalised polymer coating in sensors provides the possibility to detect, transmit and record the information regarding the concentration change or the presence of a specific analyte (a chemical or biological substance that needs to be measured) by producing a signal proportional to the concentration of the target analyte. However, the sensor response time and signal reproducibility are limited by the visco-elastical and hysteresis behaviour of the polymer material. We propose some methods improving the properties of the chemical sensors on the basis of thermo-shrinking N-isopropylacrylamide (NIPAAm) copolymer gels.     

Spectroscopic on-line monitoring of reactions in dispersed medium: chemometric challenges

Emulsion and suspension polymerizations are important industrial processes for polymer production. The end-user properties of polymers depend strongly on how the polymerization reactions proceed in time (i.e. a batch or semicontinuous, rate of reagents feeding, etc.). In other words, these reactions are process dependent, which makes the successful process control a key point to ensure high-quality products. In several process control strategies the on-line monitoring of reaction performance is required. Due to the multiphase nature of the emulsion and suspension processes, there is a lack of sensors to perform successful on-line monitoring. Near infrared and Raman spectroscopies have been pointed out as useful approaches for monitoring emulsion and suspension polymerizations and several applications have been described. In such instance, the chemometric approach on relating near infrared and Raman spectra to polymer properties is widely used and has proven to be useful. Nevertheless, the multiphase nature of emulsion and suspension polymerizations also represents a challenge for the chemometric approach based on multivariate calibration models and demands the development of new methods. In this work, a set novel results is presented from the monitoring of 15 batch emulsion reactions that show the chemometric challenge to be faced on development of new methods for successful monitoring of processes taken under dispersed medium. In order to discuss these results, several chemometric approaches were revised. It is shown that Raman and NIR spectroscopic techniques are suitable for on-line monitoring of monomer concentration and polymer content during the polymerizations, as well as medium heterogeneity properties, i.e. average particle size. It is also shown that Hotteling and Q statistics, widely used in chemometrics, might fail in monitoring these reactions, while an approach based on principal curves is able to overcome such restriction.     

FT-IR photoacoustic and x-ray diffraction study of orientation of an injection-molded liquid-crystalline poly(ester-amide)

The orientation development that takes place during injection molding of liquid-crystalline polymer (LCP) is analyzed by FT-IR photoacoustic (PA) spectroscopy and X-ray diffraction. The LCP used is the commercial Hoechst-Celanese product Vectra B 900 prepared from 6-hydroxy-2-naphthoïc acid, terephthalic acid and p-acetoxyacetanilide. The analysis reveals the so-called skin-core morphology. The highly oriented skin layer is thought to originate in the advancing melt front where the “fountain flow” dominates. A less oriented transition layer due to the shear flow is located under the skin layer. The core is related to plug flow and has relatively poor orientation.     

Molecular scale modeling of polymer imprint nanolithography

We present the results of large-scale molecular dynamics simulations of two different nanolithographic processes, step-flash imprint lithography (SFIL), and hot embossing. We insert rigid stamps into an entangled bead-spring polymer melt above the glass transition temperature. After equilibration, the polymer is then hardened in one of two ways, depending on the specific process to be modeled. For SFIL, we cross-link the polymer chains by introducing bonds between neighboring beads. To model hot embossing, we instead cool the melt to below the glass transition temperature. We then study the ability of these methods to retain features by removing the stamps, both with a zero-stress removal process in which stamp atoms are instantaneously deleted from the system as well as a more physical process in which the stamp is pulled from the hardened polymer at fixed velocity. We find that it is necessary to coat the stamp with an antifriction coating to achieve clean removal of the stamp. We further find that a high density of cross-links is necessary for good feature retention in the SFIL process. The hot embossing process results in good feature retention at all length scales studied as long as coated, low surface energy stamps are used.     

On-line monitoring of Brookhart polymerization by electrospray ionization mass spectrometry

For the first time, an electrospray ionization (ESI) mass spectrometer coupled on-line with a microreactor permitted the fast screening of polymerization growth of alkenes in the liquid phase mediated by palladium Brookhart catalyst and allowed the direct mass spectrometric identification of alkyl chains still bonded to Pd. The method also allowed us to intercept the catalytically active cationic intermediates of the Brookhart polymerization of alkenes, and to prove on-line their catalytic activity through ion/molecule reactions. The technique is fast and sensitive, requires no sample preparation and manipulation, and is therefore suitable for the fast screening of catalyst/polymer growth by MS identification, with potential applications in areas such as new catalyst development, polymer chemistry, and product quality monitoring in manufacturing.     

Mechanism for effect of ultrasound on polymer melt in extrusion

This paper explores the rheological characteristic and molecular mechanism of the polymer melts during extrusion when ultrasound is applied to them at the entrance of the die. Applying of ultrasound disturbs the convergent flow of polymer melt in the entry zone and changes the stream patterns, which leads to lesser elastic tensile strains happen. It also activates the molecular chains, so that the elastic tensile strains can be recovered very quickly. That is why the ΔP measured is reduced. These conclusions are made based not only on rheological calculations but also on looking‐inside characterizations of the molecular conformations. Ultrasound irradiation increases the free volume of PS, reduces the molecular entanglements of polymer melt. All these effects of ultrasound contribute to the productivity raising and product quality improvement of extrusion processing. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 1226–1233, 2007     

Adhesives: a new class of polymer coatings for surface acoustic wave sensors for fast and reliable process control applications

Fast and reliable on-line detection of organic vapors for control of chemical processes is a challenging application for a new type of analytical instruments: sensor systems based on an array of differently selective chemical sensors. In this work we present the use of mass-sensitive polymer coated surface acoustic wave sensors (SAWs). The sensors were initially coated with a standard set of polymers consisting of a known composition. But this first approach could not meet all requirements. Therefore, a new class of commercially available polymer coating, namely adhesives, was developed. The coating procedure was optimized and the aging process of the adhesives was carefully investigated. As a result the selectivity for ambitious separation problems arising from similar polarity of the components of typical solvent mixtures could be remarkably increased. The system was then applied in a real testing environment application at a chemical plant: the fast on-line control of a preparative reversed phase process HPLC (RP-PHPLC). Data from this industrial application are shown.     

同向啮合双螺杆挤出机挤出过程的计算机模拟

计算机模拟研究了聚苯乙烯在TSE-35A型同向啮合双螺杆挤出机的挤出过程.计算得到不同喂料速率与不同转速下的停留时间分布,并与在线荧光法测量值对比,二者基本相符.确定了停留时间与螺杆转速及喂料速率之间的函数关系式.模拟结果还预测了喂料速率、螺杆转速等工艺参数对双螺杆内流场变量,如温度、填充率、压力及粘度等的影响.模拟计算有助于了解双螺杆挤出机内部聚合物材料流动状态及停留时间长短,从而指导实际聚合物生产.     

Use of FT-IR Spectrometry for On-Line Detection in Temperature Rising Elution Fractionation

Summary: Temperature rising elution fractionation (TREF) has become a popular analytical technique that is able to determine the chemical composition distribution (CCD) of an ethylene/α-olefin copolymer. An infrared (IR) detector is commonly used in TREF detection to measure the concentration of the polymer solution exiting the column as a function of elution temperature. The chemical composition of the eluting polymer at a given elution temperature can be predicted from the relationship between comonomer content and TREF elution temperature pre-established through ¹³C nuclear magnetic resonance (NMR) analysis of TREF fractions. In this article, a Fourier transform infrared (FT-IR) spectrometer has been coupled with a TREF instrument to provide a more powerful tool for characterizing complex olefin copolymers. The Partial Least Squares (PLS) technique is used when analyzing the FT-IR spectra of the eluting polymer solutions. The power of on-line FT-IR detection in TREF is demonstrated using a few complex copolymer systems, such as ethylene-octene copolymer, polystyrene grafted ethylene-vinyl acetate copolymer and ethylene-methyl acrylate copolymer.     

Accelerating research into bio-based FDCA-polyesters by using small scale parallel film reactors

High Throughput experimentation has been well established as a tool in early stage catalyst development and catalyst and process scale-up today. One of the more challenging areas of catalytic research is polymer catalysis. The main difference with most non-polymer catalytic conversions is the fact that the product is not a well defined molecule and the catalytic performance cannot be easily expressed only in terms of catalyst activity and selectivity. In polymerization reactions, polymer chains are formed that can have various lengths (resulting in a molecular weight distribution rather than a defined molecular weight), that can have different compositions (when random or block co-polymers are produced), that can have cross-linking (often significantly affecting physical properties), that can have different endgroups (often affecting subsequent processing steps) and several other variations. In addition, for polyolefins, mass and heat transfer, oxygen and moisture sensitivity, stereoregularity and many other intrinsic features make relevant high throughput screening in this field an incredible challenge. For polycondensation reactions performed in the melt often the viscosity becomes already high at modest molecular weights, which greatly influences mass transfer of the condensation product (often water or methanol). When reactions become mass transfer limited, catalyst performance comparison is often no longer relevant. This however does not mean that relevant experiments for these application areas cannot be performed on small scale. Relevant catalyst screening experiments for polycondensation reactions can be performed in very efficient small scale parallel equipment. Both transesterification and polycondensation as well as post condensation through solid-stating in parallel equipment have been developed. Next to polymer synthesis, polymer characterization also needs to be accelerated without making concessions to quality in order to draw relevant conclusions.     

二乙醇胺改性聚乳酸的直接熔融聚合法合成及其表征

以乳酸(LA)、二乙醇胺(DEA)为原料,采用熔融聚合法直接合成了二乙醇胺改性聚乳酸,并用特性粘数、FT-IR、1H NMR、GPC、DSC、XRD等手段进行表征,探讨了催化剂种类和用量、熔融聚合反应时间、反应温度以及不同投料比、不同构型乳酸对聚合物合成的影响.在单体投料摩尔比n(DEA):n(L-LA)=1:200、160℃、70Pa、催化剂SnO用量0.7(wt)%、熔融聚合8h条件下,聚合物重均相对分子质量(Mw)可达8100.随着投料比中DEA的增加,产物特性粘数逐步降低,Mw逐渐减小,玻璃化温度(Tg)有降低的趋势.以L-LA聚合得到的聚合物的Mw、分散度(Mw/Mn)和结晶度均比由D,L-LA得到的产物的更高.因此,笔者认为,由于D,L-A与L-LA存在反应速率差异,因而二者有不同的反应历程.新合成方法有利于降低二乙醇胺改性聚乳酸作为药物缓释载体等生物医学材料的合成成本.     

Colour formation in poly(ethylene terephthalate) during melt processing

The discolouration, that occurs in virgin poly(ethylene terephthalate) - PET during melt processing, was studied using various bulk and surface analytical techniques. Proton nuclear magnetic resonance (¹H NMR) was used to study the bulk chemical changes occurring in the polymer during thermo-oxidative degradation. Chemical derivatisation with trifluoroacetic anhydride (TFAA) was used to label the hydroxyl groups introduced on the polymer surface by thermal oxidation.From the surface analysis studies using photoacoustic Fourier transform infrared spectroscopy (PA/FT-IR), diffuse reflectance infrared Fourier transform spectroscopy (DRIFT) and X-ray photoelectron spectroscopy (XPS) it was evident that colour formation starts initially with the hydroxylation of the terephthalic ring. Further, the formation of additional carbonyl functionalities and conjugated chromophoric systems complete the colour formation process.