Physico-chemical aspects of polyethylene processing in an open mixer. Part 23: Mechanisms and kinetics of trans-vinylene group consumption

There are many potential reactions for trans-vinylene groups in oxidizing polyethylene melts. The main possibilities are reactions with peroxy radicals, molecular oxygen, hydroperoxides and peracids. These different reactions can all contribute to the removal of trans-vinylene groups to some extent. This is especially so, for the reactions with hydroperoxides that have been found to be the dominant reactions with vinylidene and vinyl groups in the low temperature range. The reaction with peroxy radicals is thought to be as important relatively as with vinylidene groups. Therefore, the importance of the reaction is decreasing with increasing temperature. However, the most characteristic reaction for trans-vinylene groups can be detected without any doubt only in the advanced stages of processing. It is mechanical stress induced oxygen addition to the double bond. The discussion shows that the reaction should be important from the beginning of processing. The reaction cannot operate with vinyl and vinylidene groups, which are not part of the polyethylene main chain. After oxygen addition to the trans-vinylene group, the “ene” reaction yields an allylic hydroperoxide so that the double bond is not immediately removed. It is acid catalyzed hydroperoxide decomposition that leads to chain scission with aldehyde formation at the new chain ends.     

Physico-chemical aspects of polyethylene processing in an open mixer. Part 29: Experimental kinetics and mechanisms of γ-lactone formation

The experimental kinetics for γ-lactone formation shows more complexity than that for acids. Nonetheless, it can be concluded to the existence of a constant rate of formation from the beginning of the experiments with polyethylene melts. There is an additional term contributing to γ-lactone formation in the initial stages that is cubic in processing time. In the advanced stages of processing, in the high temperature range (170-200 °C), the concentration of γ-lactones increases linearly with the processing time.There are many mechanisms susceptible to give γ-lactones on polyethylene melt processing. Some of them are based on decomposition of intermediates formed directly on chain propagation. This is so for the α,γ-keto-hydroperoxides in 4-position to hydroxyl groups. Since decomposition of these intermediates is very fast, the reaction might account for a constant rate of γ-lactone formation from the beginning of polyethylene processing. Decomposition of the α,δ-keto-hydroperoxides formed on intramolecular reactions on chain propagation is not so fast as that of the α,γ-keto-hydroperoxides. Nonetheless, it might account for part of the delayed formation of γ-lactones. The same is valid for the mechanisms based on peroxidation of aldehydes and γ-hydroxy trans-vinylene groups that involve intermediates that are formed on polyethylene peroxidation. They might be important for explaining the cubic term as well as γ-lactone formation in the advanced stages of polyethylene processing.     

Physico-chemical aspects of polyethylene processing in an open mixer. Part 28: Formal kinetics of aldehyde and carboxylic acid formation in the advanced stages

The rate of acid formation at high temperature is constantly increasing but temperature independent. Two main mechanisms can account for this behavior in the advanced stages of polyethylene processing. The first mechanism is based on free radical induced oxidation of aldehyde pairs that are formed on acid-catalyzed decomposition of allylic hydroperoxides. The last will be formed essentially on mechanical stress-induced oxygen addition to trans-vinylene groups. Peroxidation of one of the aldehydes might yield an acyl-peroxy radical that is likely to abstract the labile hydrogen atom from the second aldehyde. The acyl radical formed in the reaction will abstract a hydroxyl group from the peracid formed in the same reaction. This yields an acid and an acyl-oxy radical that will give a primary alkyl radical on decarboxylation. The second mechanism involves oxidation of ketones and alcohols that accumulate in the oxidizing melt. Acid-catalyzed decomposition of the α-keto-hydroperoxides yields simultaneously an acid and an aldehyde. Formal kinetics based on each mechanism shows that they do not involve significant activation energy, as it is required by the experimental data. The dependency on the oxygen concentration deduced from the formal kinetics for the oxidation of aldehyde pairs is in agreement with the experiments.     

Physico-chemical aspects of polyethylene processing in an open mixer. Part 32: Formal kinetics of γ-lactone formation from secondary products. Heterogeneous kinetics

Oxidation of aldehydes and γ-hydroxy-trans-vinylene groups can yield γ-lactones. These intermediates account for γ-lactone formation in the advanced stages of polyethylene processing in air. The acyl-peroxy radical formed on free radical induced oxidation of aldehydes can abstract intramolecularly a δ-hydrogen atom to yield a peracid. Reaction of the alkyl radical formed in this reaction with the hydroperoxide group of the peracid gives a γ-lactone with simultaneous release of a hydroxyl radical. The calculated rate of γ-lactone formation according to the mechanism envisaged decreases slightly with increasing temperature (activation energy of about −5 kcal/mol). It is in agreement with the experiments that do not show significant activation energy in the high temperature range for the advanced stages of polyethylene processing. The calculated rate of γ-lactone formation is found to increase by a factor of about 2.7 if the processing experiments are performed in pure oxygen instead of in air. This is close to the experimental factor of about 2.Peroxidation of γ-hydroxy-trans-vinylene groups can also yield γ-lactones. The first possibility involves addition of a peroxy radical to the double bond followed by oxygen addition to the alkyl radical. This reaction possibly yields an α-peroxy-hydroperoxide. Intramolecular decomposition involving the two reactive groups of the α-peroxy-hydroperoxide can give an ozonide that on thermal decomposition yields among others an acid group in 4-position to the alcohol. The activation energy calculated is strongly negative so that the rate should decrease strongly with increasing temperature. Hence, the mechanism cannot contribute significantly to γ-lactone formation in the whole temperature range of the experiments. This is so in spite of the fact that the rate is estimated to increase by a factor of about 1.7 on passing from air to pure oxygen, which is close to the experimental value of approximately 2. The second possibility of transformation of γ-hydroxy-trans-vinylene groups is based on stress-induced oxygen addition to the double bond. Acid catalyzed decomposition of the allylic hydroperoxide that is formed in the reaction yields a pair of aldehydes with one of the aldehyde groups in 4-position to the alcohol group. Peroxidation of the aldehyde pair can give an acid group in 4-position to the hydroxyl group so that a γ-lactone can be formed. The activation energy calculated for the process is very small and the effect of the oxygen concentration corresponds to an increase by a factor of approximately 4.5 on passing from air to pure oxygen. It is postulated that simultaneous contribution by different mechanisms might well account for the experimental value of about 2.The heterogeneous kinetics discussed in detail allows for complementary data interpretation. It is especially suited for the understanding of the advanced stages of polyethylene processing, after some induction time.     

Thermolysis of polyethylene hydroperoxides in the melt, Part 10: Product yields from bimolecular and pseudo-monomolecular hydroperoxide decomposition

The quantitative aspects of some specific decomposition reactions of polyethylene hydroperoxides are re-examined. New data have shown that β-scission of primary alkoxy radicals is negligible in the temperature range of the thermolysis experiments. This is important for the true bimolecular hydroperoxide decomposition for which, in a first approximation, β-scission of primary and secondary alkoxy radicals had been taken into account. The calculation shows that the yields of the main oxidation products such as secondary alcohols, ketones, trans-vinylene groups and aldehydes are not considerably affected by the change. However, the theoretical yields of some minor products such as primary alcohols and of some combination reactions are strongly affected. For the pseudo-monomolecular hydroperoxide decomposition involving a segment of the polymer, the main novelty in comparison with previous work consists in taking into account β-scission of the secondary alkoxy radicals. It allows improving the accuracy of the calculated product yields. Moreover, all the theoretical calculations are on the same level of accuracy and can be used for comparison with the experimental product yields.     

Kinetic study of the γ radiolysis of polyethylene

A kinetic study was made of the formation of hydrogen and trans-vinylene unsaturation in the radiolysis of polyethylene induced by γ rays with a dose rate of 6.35 × 10⁵ rad/hr at 30–100°C in vacuo. The rates of the formation of hydrogen and trans-vinylene unsaturation were described by the zero-order formation kinetics with respect to each concentration combined with the first-order disappearance. The apparent rate constant for the formation of hydrogen increased gradually with rising irradiation temperature to give the activation energy of 0.6 kcal/mole. On the other hand, those for the disappearance of hydrogen and the formation and disappearance of trans-vinylene unsaturation were almost independent of temperature. The G values for crosslinking and main-chain scission were obtained from the gel data by using the Charlesby-Pinner equation, and the activation energy of 1.5 kcal/mole was given for both of them. On the basis of these results the reactions induced by γ rays in solid polyethylene were discussed.     

Effects of electron beam preirradiation on the γ radiolysis of polyethylene

The γ radiolysis of polyethylene preirradiated with electron beams to 3 Mrad was carried out at 30–100°C in vacuo with a dose rate of 6.35 × 10⁵ rad/hr. The hydrogen formation in the γ radiolysis was little affected by the preirradiation of electron beams, whereas the formation of trans-vinylene unsaturation and gel was somewhat retarded. The rates of the formation of hydrogen and trans-vinylene unsaturation were described by the zero-order formation kinetics with respect to each concentration combined with the first-order disappearance. The apparent rate constants and activation energies for the formation and disappearance of hydrogen and trans-vinylene unsaturation were almost independent of the preirradiation. The gel fraction was analyzed by using the Charlesby–Pinner equation. The G values of crosslinking and main chain scission were increased by the preirradiation, whereas their activation energies remained unaltered. On the basis of these results the effects of preirradiation on the reactions induced by γ rays in polyethylene were discussed.     

γ Radiolysis of polyethylene grafted with styrene

γ Radiolysis of polyethylene grafted with styrene of 0–76 wt % was carried out at 30–100°C in vacuo with a dose rate of 6.35 × 10⁵ rad/hr. The formation of hydrogen and trans-vinylene unsaturation decreased as the content of styrene unit in polymer increased and the rate of formation was described by zero-order formation kinetics with respect to each concentration combined with first-order disappearance. The gel fraction changed with the content of styrene unit according to irradiation time and temperature. The gel data were evaluated by using the Charlesby–Pinner equation. Kinetic analysis showed that in γ radiolysis of polyethylene grafted with styrene the formation of hydrogen is somewhat retarded, the crosslinking and main chain scission are accelerated, and the disappearance of hydrogen and formation and disappearance of trans-vinylene unsaturation are almost entirely unaffected. On the basis of these results the reactions induced by γ rays in graft polymer were discussed in connection with the reaction mechanisms of the γ radiolyses of polyethylene and polystyrene.     

Physico-chemical aspects of polyethylene processing in an open mixer. Part 21: Improved product yields on true bimolecular hydroperoxide decomposition

The product yields from the reaction between two hydroperoxide groups have been re-calculated. This is a consequence of the fact that β-scission of secondary alkoxy radicals cannot be neglected in the high temperature range of the polyethylene processing experiments (170-200 °C). It must be taken into account in addition to disproportionation/combination and hydrogen abstraction by alkoxy radicals. The increased complexity caused by the additional reaction results mainly from the larger number of caged radical pairs involved in the reactions and also in the calculations. Among other products it becomes possible to calculate the yields of aldehyde and vinyl groups that would not result from hydroperoxide decomposition in the absence of β-scission. The yields of the main oxidation products such as alcohols, ketones and trans-vinylene groups are reduced to some extent in comparison with the values calculated if β-scission is neglected. The vinyl group yield corresponds to slightly more than 10% of the yield of trans-vinylene groups in the temperature range of the experiments. The aldehyde yield is significantly larger than the vinyl group yield and is important in the whole temperature range examined. Main-chain scissions are important at the temperatures of the experiments. They become more important than the sum of the different combination reactions from a temperature of 200 °C on.     

Physico-chemical aspects of polyethylene processing in an open mixer. Part 20: Additional product yields on bimolecular hydroperoxide decomposition with an alcohol group

Most products formed on polyethylene oxidation result from hydroperoxide decomposition. The product yields can be calculated for various mechanisms of hydroperoxide decomposition. This work concerns the reaction of a hydroperoxide with an alcohol group thought to be dominant in the advanced stages of polyethylene processing in the high temperature range (170-200 °C). Besides hydrogen abstraction by caged alkoxy radicals already envisaged previously, the possibility of β-scission is taken into account. This additional reaction introduces significant complexity into the reaction schemes. This is especially so because additional caged radical pairs must be included into the schemes and the calculations. It becomes possible to calculate the yields of aldehyde and vinyl groups that do not result from hydroperoxide decomposition in the absence of β-scission. The yields of the main oxidation products such as alcohols and ketones are not much affected by taking into account β-scission. The yield of aldehydes is important in the whole temperature range and increases considerably if the temperature is raised from 170 to 200 °C. It becomes more important than the ketone yield. The vinyl groups are formed in amounts corresponding roughly to 10-15% of the trans-vinylene groups in the temperature range of 170-200 °C.     

Physico-chemical aspects of polyethylene processing in an open mixer. Part 24: Experimental kinetics of aldehyde and carboxylic acid formation

The experimental kinetics for carboxylic acids shows more complexity than that for ketones. The fitting of the experimental results for the initial stages to the equation consisting of a linear and a quadratic term in processing time accounts well for the ketone data but not for the acid data. Instead of that, the data for the acids show fair fit to an equation containing a linear term and another term that is cubic in processing time. In the temperature range of the experiments the linear term is practically constant. The cubic term increases strongly with temperature. The combination of a linear and a quadratic term can account for the advanced stages of processing. The corresponding quadratic term shows strong increase if the processing temperature passes from 150 to 160 °C. However, for higher processing temperatures it remains constant within experimental error. The difference carbonyl absorbance measured after treatment of the polyethylene films with ammonia corresponds to the sum of the acids and aldehydes. It shows similarly complex kinetics. Some of the difficulties encountered with the experimental kinetics cannot be resolved with the data available. It is only the comparison with the formal kinetics based on potential mechanisms of product formation that allows for better understanding of the experimental results.     

Physico-chemical aspects of polyethylene processing in an open mixer. Part 26: Formal kinetics of aldehyde and carboxylic acid formation at a constant rate

Formation of carboxylic acids at a constant rate can be easily explained. It seems to result from the formation and decomposition of α,γ-keto-hydroperoxides. Formal kinetics based on formation and decomposition of these structural units is in agreement with the experimental findings. The activation energy deduced from the calculations is negligible, in agreement with the experimental data showing the constant rate to be practically temperature independent. Comparison of the acids with the hydroperoxides and ketones formed initially shows that the rate of oxygen addition to alkyl radicals is significantly smaller than in low molecular mass liquids. The same conclusion is reached on comparing directly the acids formed on decomposition of α,γ-keto-hydroperoxides in polyethylene melt and in hexadecane. The rate of oxygen addition in polyethylene melt is closer to 2 × 10⁵ than to 6 × 10⁵ (s⁻¹) that is valid in hexadecane.It is possible to attribute the relatively small amount of aldehydes that might be formed at a constant rate to different reactions of alkoxy radicals that are not in a cage with other radicals. These alkoxy radicals result from the addition of peroxy radicals to unsaturated bonds. This addition is followed mainly by epoxide formation and simultaneous release of an alkoxy radical.     

Physico-chemical aspects of polyethylene processing in an open mixer. Part 17. Effect of oxygen availability

The gas in contact with polyethylene has considerable impact on its oxidation. The rate of oxidation product formation is mostly larger with oxygen blanketing than in air. Similarly, the rate in air is larger than that under nitrogen blanketing. Moreover, the relative effect of the surrounding gas is depending heavily on the particular oxidation product considered. The effect on the alcohol concentration on passing from air to pure oxygen is the same as that on the hydroperoxide concentration. It is only under pure nitrogen that alcohol formation is relatively more affected than hydroperoxide formation. The overall carbonyl groups as well as the ketones show the expected ranking, i.e. faster rate in pure oxygen than in air and faster rate in air than under pure nitrogen. However, carboxylic acids are formed much faster in oxygen than in air. For the acids the results in air and under nitrogen are significantly closer in the initial stages of processing than the results obtained under pure oxygen. This is different for γ-lactones for which formation is faster in oxygen than in air where it is faster than under nitrogen. With trans-vinylene groups the situation is opposite to that observed for carboxylic acids: the rate of formation is close for the experiments performed under air and under oxygen and significantly faster than under nitrogen. The results for hydroperoxides, alcohols and ketones are easily interpreted taking into account the kinetics developed in previous work. Fitting the data to the heterogeneous kinetics shows the effect of the oxygen concentration on this kinetics. It is especially unexpected with respect to its impact on the initiation rate. It is discussed taking into account various possibilities. The only one that is compatible with all the data envisages chain initiation resulting from interaction of oxygen with strained polymer molecules.     

Identifying crosslinks in polyethylene following gamma-irradiation in acetylene: A model compound study

Long-chain linear alkanes have been used as model compounds for polyethylene in an attempt to identify the chemical nature of crosslinks formed in polyethylene when it undergoes γ-irradiation in the presence of acetylene. IR and UV spectral analysis of alkanes and polyethylene following acetylene-sensitized irradiation shows the formation of vinyl, trans-vinylene, and diene groups. A correlation of the conditions of formation suggests that in polyethylene the vinyl groups are restricted to amorphous regions, diene groups are restricted to the crystalline regions, and trans-vinylene groups are formed in both regions. There is no information on the nature of crosslinks. ¹³C-NMR analysis of alkanes following irradiation of molten alkanes in the presence of ¹³C-enriched acetylene has shown that a range of saturated alphatic structures are formed by inclusion of acetylene molecules in the alkane structure. They include ethyl branches, γ-branches, CH(CH₃) , and  CH₂ CH₂ branches as the major species; the latter two are potential crosslink sites in the irradiation of polyethylene. In addition, the NMR analysis confirmed that the C atoms of the vinyl groups come from acetylene molecules and those of the trans-vinylene groups come from alkane molecules. Data on irradiation of the alkanes in the crystalline state showed that acetylene inclusion in the alkane structure is minimal under these conditions. The principal finding of this work is that acetylene can be incorporated as saturated aliphatic crosslinks in the amorphous regions of polyethylene during high-energy irradiation. © 1997 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 35: 1549–1561, 1997     

Determination of chemical structures by 1H- and 13C-NMR for thermally degraded linear high density polyethylene

Chemical structures were determined for polymer residues obtained by thermal degradation of a linear high-density polyethylene. Terminal methyl, double bonds (terminal vinyl, trans-vinylene, and vinylidene), and long chain branching were identified by using ¹H- and ¹³C-NMR spectra data. The number of these functional groups per 1000 C was quantified with a relative error of about 10%.     

Melt stabilisation of Phillips type polyethylene, Part I: The role of phenolic and phosphorous antioxidants

The role of a phenolic and three phosphorous (phosphite, phosphonite and phosphine) antioxidants in the melt stabilisation of polyethylene was studied in a Phillips type polyethylene by multiple extrusions. The polyethylene was stabilised with a single antioxidant at 700 ppm and with phenolic/phosphorous antioxidant combinations containing 700 ppm of each component. The functional groups (methyl, vinyl, vinylidene, trans-vinylene and carbonyl) of polyethylene and the residual amount of phosphorous antioxidants were analysed quantitatively by FT-IR methods developed in our laboratory. The rheological characteristics, the colour and the residual thermo-oxidative stability of the polymer were determined and compared. Blown films were prepared and their mechanical strength measured by the Elmendorf and Dart-drop tests. The comparison of the different characteristics revealed that the chemical reactions taking place during the first processing of the nascent polymer powder, as well as the chemical composition of the antioxidants determine the reactions taking place in further processing operations. The changes in the characteristics of stabilised polyethylene during processing are controlled by the phosphorous stabiliser. The effect and final result depend on the chemical structure of the given antioxidant. The phenolic antioxidant itself does not hinder the formation of long chain branches. It reduces the rate of oxidation of the various phosphorous stabilisers, but does not modify the mechanism of stabilisation of the phosphonite and the phosphine. The reactions of the phosphite are significantly modified by the presence of a phenolic antioxidant.     

All ring compounds—XXIX : Thermal decomposition of t-butyl per (trans-2-substituted cyclopropyl) acetates

Three kinds of t-butyl per (trans-2-substituted cyclopropyl) acetates (RH, CH₃, C₆H₅) were synthesized from the corresponding acyl chlorides and thermally decomposed in cyclohexane to investigate the chemical stability and behaviour of the cyclopropylcarbinyl radical. Clean first-order kinetics were obtained in all of the thermal decomposition reactions. The experimental fact that the decompositoin rates and activation parameters of these three t-butyl peresters are similar to each other may indicate the absence of the ionic character in the transition state suggesting the almost complete homolytic decomposition of these peresters. Although the typical concerted decomposition might be invalid for these peresters in view of the activation parameters, it would be suggested from the product studies that the decomposition of these peresters was characterized by a considerable loss of their acyl-alky] bonds at the time of the fission of their OO bonds. The products yielded from the thermal decomposition of t-butyl per (trans-2-phenylcyclopropyl) acetate in various hydrogen donating solvents consisted of three hydrocarbons and two t-butyl ethers. The formation of these t-butyl ethers, possibly cage products, was significant.     

Irradiation of ultrahigh-molecular-weight polyethylene

An ultrahigh-molecular-weight polyethylene material covering a range of crystallinity from 42 to 79% increased in calorimetric crystallinity as a result of chain scission following ionizing irradiation. Carbonyl was formed by a diffusion-limited reaction of oxygen with long-lived free radicals. Trans-vinylene production was linear with radiation dose and was highest for the sample of highest crystallinity but was not sensitive to environment.     

Radiation chemistry of linear low-density polyethylene. II. Kinetics of alkyl and allyl free-radical decay reactions

Quenched and annealed samples of linear low-density polyethylene (LLDPE) were γ irradiated in vacuo at 77 K; the kinetics of the alkyl free-radical decay reactions were studied at room temperature, and of the allyl free-radical reactions at 60, 70, and 80°C. The ESR signals saturate at a slightly higher microwave power in the LLDPE than in high-density polyethylene (HDPE), and the alkyl radicals start decaying at a lower temperature in the LLDPE than in the HDPE. As in the HDPE the decay of the alkyl free radicals at room temperature in the LLDPE follows the kinetic equation for two simultaneous first-order reactions with the fraction of the faster-decaying component being slightly greater in the quenched than in the annealed samples. In the case of the allyl free radicals the decay at 60°C follows the equation based on one fraction of the radicals decaying according to second-order kinetics in the presence of other nondecaying radicals. At higher temperatures the data are best understood in terms of a second-order rate equation with a continuously variable time-dependent rate constant as suggested by Hamill and Funabashi.