Influence of micromixing on the free-radical polymerization in a discontinuous process

With the help of a simple reaction-diffusion model with constant striation thickness the influence of micromixing on free-radical polymerization was investigated for several test reactions with discontinuous prepolymerization and jerky addition of selected reactants. Monomer conversion or mean values of molar mass and chemical composition cannot be expected to be very sensitive to micromixing effects. If molar mass distributions are to be used, problems will arise from the fact that the distribution of the polymer accumulated during prepolymerization covers mixing influences occurring after reactant feed. The instantaneous molar mass distribution would be more suitable. Time-integral distributions of chemical composition or sequence length in combination with appropriate test reactions proved to be feasible indicators for the effects of micromixing as it becomes possible to separate the distribution of the prepolymer from that of the polymer which is formed after addition when micromixing is to be investigated.     

Controlled synthesis of poly(dimethylsiloxane) homopolymers using high‐vacuum anionic polymerization techniques

The controlled synthesis of poly(dimethylsiloxane) homopolymers (PDMS) using hexamethyl(cyclotrisiloxane) monomer (D₃), a mixture of ciclohexane/tetrahydrofuran 50/50 v/v and sec‐Bu^–Li⁺ as initiator was studied using different experimental conditions, and whole‐sealed glass reactors according to standards procedures in high‐vacuum anionic polymerization. It was observed that polydispersity indexes (PD) and conversions strongly depend on temperature and reaction times. For PDMS homopolymers with molar masses below 100,000 g/mol, high conversion (>90%) and PD < 1.1 can be achieved at long reaction times (24 h) and mild temperature conditions (below or up to 30 °C). On the other hand, to synthesize PDMS homopolymers with molar masses higher than 100,000 g/mol and PD < 1.1 it is necessary to increase the temperature up to 50 °C and decrease the reaction time (8 h). However, under these reaction conditions, it was observed that the conversion decreases (about 65–70% conversion is achieved). Apparently, the competition between propagation and secondary reactions (redistribution, backbiting, and reshuffling) depends on the molar masses desired. According to the results obtained in this study—which were compared with others found in the scientific literature—propagation is favored when M_n < 100,000 g/mol, whereas secondary reactions seem to become important for higher molar masses. Nevertheless, model PDMS homopolymers with high molar masses can still be obtained increasing the reaction temperature and shortening the total reaction time. It seems that the combined effect of these two facts favors propagation against secondary reactions, and provides model PDMS homopolymers with molar masses quite close to the expected ones. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 4774–4783, 2009     

Recent Advances in Automatic Continuous Online Monitoring of Polymerization Reactions (ACOMP)

ACOMP allows comprehensive, model-independent, near realtime monitoring of many different types of polymerization reactions. It provides conversion kinetics, and the evolution of average molar mass, intrinsic viscosity and average composition distributions (for copolymers). Here, recent advances in ACOMP will be summarized, dealing with continuous reactors, copolymerization, ‘living’ type reactions (NMP, RAFT, ATRP, ROMP), polyelectrolytes, heterogeneous phase reactions, including free radical reactions in emulsions, and predictive control. In the case of emulsion polymerization, a new approach will be presented in which the evolution of the characteristics of both the soluble phase – monomer conversion, polymer molar mass and intrinsic viscosity- and the dispersed phase – particle size – are simultaneously monitored. NSF CBET 0623531, BoR ITRS 019B, NASA NCC3-946, TIMES, PolyRMC (Tulane Center for Polymer Reaction Monitoring and Characterization).     

Comparing Long‐Chain Branching Mechanisms for Ethylene Polymerization with Metallocenes and Other Single‐Site Catalysts: What Simulated Microstructures Can Teach Us

Three different long‐chain branch (LCB) formation mechanisms for ethylene polymerization with metallocenes in solution polymerization semi‐batch and continuous stirred‐tank reactors are modeled to predict the microstructure of the resulting polymer. The three mechanisms are terminal branching, C–H bond activation, and intramolecular random incorporation. Selected polymerization parameters are varied to observe how each mechanism affects polymer microstructure. Increasing the ethylene concentration during semi‐batch polymerization reduces the LCB frequency of polymers made with the terminal branching and intramolecular mechanisms, but has no effect on those made with the C–H bond activation mechanism, which disagrees with most previous data published in the literature. The intramolecular mechanism predicts that LCB frequencies hardly depend on polymerization time or ethylene conversion, which also disagrees with the published experimental data for these systems. For continuous polymerization reactors, experimental data relating polydispersity to LCB frequency can be well described with the terminal branching mechanism, but both C–H bond activation and intramolecular models fail to describe this experimental relationship. Therefore, detailed simulations confirm that the terminal branching mechanism is indeed the most likely mechanism for LCB formation when ethylene is polymerized with single‐site coordination catalysts such as metallocenes in solution polymerization reactors.     

β-Myrcene Coordination Polymerization: Experimental and Kinetic Modeling Study

The present work presents phenomenological models to describe the coordination polymerization of β-myrcene using the Ziegler–Natta catalyst system composed by neodymium versatate (NdV₃), diisobutylaluminum hydride (DIBAH), and dimethyldichlorosilane. The kinetic parameters required to simulate the reactions are estimated, and the amount of DIBAH used as a chain transfer agent (CTA) is obtained by a data reconciliation strategy since it can participate in side reactions. Several experiments are performed at different conditions to evaluate the impact of key operation variables on the control of monomer conversion and average molar masses. It is shown that the initial NdV₃, β-myrcene, and DIBAH concentrations exert strong influences on the course of the polymerization. The kinetic mechanism of Coordinative Chain Transfer Polymerization (CCTP) fits well with the data of final average molar masses and monomer conversion, while the dynamic trajectories of these variables are fitted better by kinetic mechanisms of more conventional coordination polymerizations, considering site deactivation and termination by chain transfer. In all cases, the proposed models are able to predict the experimental data well after successful parameter estimation and reconciliation of CTA concentrations, indicating that the kinetic mechanism can be characterized by different kinetic regimes.     

Characterization and rheological properties of model alkali‐soluble rheology modifiers synthesized by reversible addition–fragmentation chain‐transfer polymerization

Model alkali‐soluble rheology modifiers of different molar masses were synthesized by the reversible addition–fragmentation chain‐transfer polymerization of methyl methacrylate, methacrylic acid, and two different associative macromonomers. The polymerization kinetics showed good living character including well‐controlled molar mass, molar mass linearly increasing with conversion, and the ability to chain‐extend by forming an AB block copolymer. The steady‐shear and dynamic properties of a core‐shell emulsion, thickened with the different model alkali‐soluble rheology modifiers, were measured at constant pH and temperature. The steady‐shear data for latex solutions with conventional rheology modifiers exhibited the expected thickening, whereas the associative rheology modifiers showed contrasting rheology behavior. The dynamic measurements revealed that the latex solutions thickened with the conventional rheology modifiers exhibit solid‐like (dominant G′) behavior as compared with the associative rheology modifiers that give the latex solution a liquid‐like (dominant G″) character. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 223–235, 2003     

Development and Modeling of a Continuous Dispersion Copolymerization Process in the Presence of a Stabilizing Agent Elaborated in situ

Summary: This work deals with the development of a process for the radical copolymerization of acrylonitrile and styrene in a dispersed medium. This process was carried out in a continuous stirred tank reactor, in the presence of a stabilizing agent produced in situ during the polymerization. The continuous phase is a polyol. Besides all elementary chemical mechanisms related to the copolymerization and to the synthesis and grafting of the stabilizing agent, this process involves several complex physical phenomena. A tendency model of the whole process was developed, using the corresponding mass balances and thermodynamics. Its unknown parameters were identified by use of an evolutionary algorithm and experimental data resulting from an adapted experimental strategy. This model was then validated and allowed to predict monomers and transfer agent conversions, amounts of solids and average molar masses, versus the operating conditions.     

Design of Nonlinear Model‐Based Control Using Bifurcation Analysis for Solution Polymerizations Carried Out in Lumped‐Distributed Reactors

In order to implement nonlinear control, nonlinear system identification must be performed, however, there are open questions concerning this field of process control, for example, experimental planning, model structure selection, parameter estimation, and validation. Therefore, the study of nonlinear model identification is a relevant unsolved problem that needs to be handled for nonlinear control synthesis. This paper presents the use of bifurcation theory, dynamic and stability analysis for nonlinear identification, and control of polymerization reactors. Peroxide‐initiated styrene‐solution polymerization reactors (lumped‐distributed) are investigated: batch, continuous stirred‐tank reactor (CSTR), and tubular reactors. Open and closed loop analyses are carried out using jacket temperature and weight average molecular weight setpoints as the bifurcation parameters. Phenomenological mathematical models, neural network nonlinear models, and an experimental data from a polymerization unit are employed for validating the proposed methodology in order to implement confident nonlinear controllers.     

Modeling of elementary reactions and kinetics of radical‐initiated methyl methacrylate polymerization in the presence of ferrocene

On the basis of quantum chemical modeling, a kinetic scheme of methyl methacrylate polymerization initiated by benzoyl peroxide in the presence of ferrocene was proposed. The process runs by mechanism, which includes the reactions of free radical polymerization, and the reactions leading to formation and operability of two type coordination active sites that are capable of converting into each other. On the basis of the proposed scheme, a kinetic model was developed. This model quantitatively described the following: the experimentally determined time dependences of the methyl methacrylate conversion, the conversion dependencies of the number‐average and weight‐average molar masses of poly(methyl methacrylate), the stereoregularity values of poly(methyl methacrylate), and the time dependencies of the methyl methacrylate conversion upon its polymerization on poly(methyl methacrylate) macroinitiators obtained in radical‐initiated polymerization in the presence of ferrocene. As a result of solving the inverse kinetic problem, the parameters of temperature dependences of the reaction rate coefficients of the proposed kinetic scheme were found.     

Use of the NiBr2(PPh3)2/Zn catalytic system for homo- and copolymerization of styrene and methyl methacrylate

The regularities of methyl methacrylate and styrene (co)polymerization in the presence of catalytic systems based on a Ni(II) complex combined with zinc and an aryl halide have been studied. The effects of temperature and catalytic system components on conversion are established. The molecular masses of the polymers linearly increase with monomer conversion, thus suggesting the controlled character of the polymerization. Reactivity ratios are calculated for methyl methacrylate-styrene copolymerization (r _MMA = 0.45, r _styrene = 1.70) in the presence of NiBr₂(PPh₃)₂/Zn/PhI. The rate of copolymerization is shown to decrease with an increase in methyl methacrylate concentration. The scheme of the process is proposed based on an analysis of the experimental and literature data.     

Kinetics of hexene‐1 polymerization using [(N,N′‐diisopropylbenzene)‐2,3‐(1,8‐napthyl)‐1,4‐diazabutadiene] dibromonickel/methylaluminoxane catalyst system

Kinetics of hexene‐1 polymerization was investigated using [(N,N′‐diisopropylbenzene)2,3‐(1,8‐napthly)‐1,4‐diazabutadiene]dibromonickel/methylaluminoxane catalyst. Experiments were performed at varying catalyst and monomer concentrations in the temperature range of ?10 to 35 °C. First order time‐conversion plot shows a downward curvature at temperatures of 20 °C and 35 °C indicating the presence of finite termination reactions. A nonlinear plot of degree of polymerization (P_n) with respect to conversion indicates occurrence of transfer reactions and slow initiation. The experimental molar masses are higher than predicted, which implies that a fraction of catalyst species could not be activated or is deactivated at the early stages of the reactions. The efficiency of the catalyst (Cat_eff) varies from 0.77 to 0.89. The observed polydispersity of the poly(hexene‐1) s is in the range of 1.18–1.48. The reaction order was found to be 1.11 with respect to catalyst. The Arrhenius plot obtained using the overall propagation rate constant, k_p, at five different temperatures (?10, 0, 10, 20, and 35 °C) was found to be linear with an activation energy, E_a = 4.3 kcal/mol. Based on the results presented it is concluded that the polymerization of hexene‐1 under the above‐mentioned conditions shows significant deviation from ideal “living” behavior. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 1093–1100, 2007     

Theoretical study of chain transfer in anionic polymerization, 2. Copolymerization accompanied by chain transfer to solvent

The main factors determining molar mass characteristics of copolymers formed in nonterminating copolymerization under the conditions of chain transfer to solvent are studied theoretically. The dependences of the mean polymerization degrees on conversion and monomer feed composition for various values of reactivity ratios are obtained. The results obtained greately differ from those for homopolymerization. This is explained by the contribution of cross-propagation reactions. In particular, it is shown that at ≪ and ≪ the azeotropic copolymerization proceeds like the living one even if homopolymerization of each monomer is accompained by extensive chain transfer to solvent.     

Free‐radical copolymerization of ethyl α‐hydroxymethylacrylate with methyl methacrylate by reversible addition–fragmentation chain transfer

The controlled free‐radical homopolymerization of ethyl α‐hydroxymethylacrylate and copolymerization with methyl methacrylate were performed in chlorobenzene at 70 °C by the reversible addition–fragmentation chain transfer polymerization technique with 2,2′‐azobisisobutyronitrile as the initiator. 2‐Phenylprop‐2‐yl dithiobenzoate and 2‐cyanoprop‐2‐yl dithiobenzoate were used as chain‐transfer agents in the homopolymerization, whereas only the former was used in the copolymerization. All reactions presented pseudolinear kinetics. The effect of the monomer feed ratio on the copolymerization kinetics was examined. The conversion level decreased when the proportion of ethyl α‐hydroxymethylacrylate in the monomer feed was larger. Kinetic studies indicated that the radical polymerizations proceeded with apparent living character according to experiments, demonstrating an increase in the molar mass with the monomer conversion and a relatively narrow molar mass distribution. All copolymers were statistical in chain structure, as confirmed by determinations of the monomer reactivity ratios. The monomer reactivity ratios were determined, and the Mayo–Lewis terminal model provided excellent predictions for the variations of the intermolecular structure over the entire conversion range. Additionally, the chemical modification of poly(ethyl α‐hydroxymethylacrylate) was carried out to introduce glucose pendant groups into the structure. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 5618–5629, 2006     

Modeling Particle Size Distribution (PSD) in Emulsion Copolymerization Reactions in a Continuous Loop Reactor

A detailed dynamic mathematical model that describes the evolution of particle size distributions (PSDs) during emulsion copolymerization reactions in a continuous loop reactor was developed and compared with experimental data. The model is based on the assumption that two distinct particle populations exist: precursor particles and stable latex particles. Precursor particles are colloidally unstable and therefore may undergo coagulation with other precursors and be absorbed by stable latex particles. It is shown that the kinetic model is able to reproduce the rather complex dynamic behavior of the vinyl acetate/Veova10 emulsion copolymerization in a continuous loop reactor, including the development of oscillatory responses of PSDs during reaction start‐up. It is also shown that, for the studied polymerization system, oscillatory responses are obtained only when both particle populations are assumed to exist and when both coagulative and micellar particle nucleations are simultaneously considered.     

Effects of acrylonitrile water solubility on limiting conversion and copolymer composition in suspension polymerization

The effects of acrylonitrile (AN) water solubility on the limiting conversion and copolymer composition of the AN and AN/vinylidene chloride (VDC) suspension polymerization were investigated. It was found that AN dissolved in aqueous phase does not transfer back to oil phase in AN suspension homopolymerization but partially does in AN/VDC suspension copolymerization, and thus the limiting conversion is lowered and decreases with water/oil ratio increasing in both AN and AN/VDC suspension polymerization. For the continuous transport of AN in aqueous phase to oil phase during suspension polymerization, the composition distribution of AN/VDC copolymer prepared by suspension polymerization is narrower than that by bulk polymerization. The calculated composition of AN/VDC suspension copolymer with considering AN water solubility is consistent with the experimental data.     

Copolymerization of ethylene and vinyl acetate at low pressure: Determination of the kinetics by sequential sampling

In behalf of a detailed study on the course of copolymerization reactions, this paper describes an improved and generally applicable experimental method and an efficient computational procedure to match. The experimental method is based on quantitative gas chromatography, and permits frequent measurement of the monomer feed composition throughout (co)polymerization processes at pressures up to 40 kgf/cm² ( = 38.7 atm). The given method is applied to the study of the radical copolymerization of ethylene with vinyl acetate in a series of kinetic experiments, at 62°C and 35 kgf/cm² ( = 33.9 atm) in tert-butyl alcohol, in which 20–40% conversion is reached. Monomer feed composition and degree of conversion are entered into a computational procedure based on nonlinear least-squares methods applied to the integrated version of the copolymer equation. The experimental data, covering a region of ethylene molar feed fractions between 0.24 and 0.74 and copolymer concentrations up to 8 wt-%, are precisely consistent with the usual model. The respective reactivity ratios are r?_e = 0.743 ± 0.005 and r?_v = 1.515 ± 0.007.     

Multiscale Modeling of Mixing Behavior in a 3D Atom Transfer Radical Copolymerization Stirred‐Tank Reactor

Multiscale mixing phenomena in stirred‐tank polymerization reactors are mainly caused by stir agitation, which performs a key function in macroscopic and microscopic flow fields. Both macroscopic and microscopic flow fields interact with each other and significantly affect the microstructure and product distribution of the resultant polymers. In this work, a computational fluid dynamics model combining the moment method used in the polymerization engineering field is implemented and validated using open data. Multiscale properties are characterized in terms of macroscopic mixing fields and the polymer microscopic structure of the atom transfer radical copolymerization system of methyl methacrylate and 2‐(trimethylsilyl) ethyl methacrylate. Agitation in a 3D stirred tank is also thoroughly studied by using the multiple reference frame approach, and the effects of several important para­meters, such as impeller speed, impeller types, and feeding position, on the macroscopic and microscopic flow fields are investigated on the basis of the validated model. Interdependent relationships among agitation, multiscale flow fields, and polymerization are described clearly. The results highlight the function of stirring and provide useful guidelines for the scale‐up of stirred‐tank polymerization reactors.

     

Free‐Radical Frontal Copolymerization: The Dependence of the Front Velocity on the Monomer Feed Composition and Reactivity Ratios

Frontal copolymerization is a process in which a spatially localized reaction zone propagates into a mixture of two monomers, converting them into a copolymer. In the simplest case of free‐radical copolymerization, a mixture of monomers and initiator is placed into a test tube. Reaction is initiated at one end of the tube, and a self‐sustained thermal wave, in which chemical conversion occurs, develops and propagates through the tube. We develop a mathematical model of the frontal copolymerization process and analytically determine the structure of the polymerization wave, the propagation velocity, maximum temperature, and degree of conversion of the monomers. Specifically, we examine their dependence on reactivity ratios as well as other kinetic parameters, monomer feed composition, and exothermicity of the reactions. Our analytic results are in good quantitative agreement with both direct numerical simulations of the model and experimental data, which are also presented in the paper.

Dependence of front velocity on monomer feed composition for different heat release parameters.     

Acrylamide inverse microemulsion polymerization in a paraffinic solvent: Rolling‐M‐245

The inverse microemulsion polymerization of acrylamide in a paraffinic solvent, Rolling‐M‐245, stabilized by a mixture of nonionic surfactants (Emulan‐ELP‐11 and Brij‐92), was studied. Pseudoternary phase diagrams of this system were determined, and a range of hydrophilic‐lipophilic balance (HLB) values, from 8.98 to 9.2, were selected as the most favorable for acrylamide polymerization. The influence of factors such as the initiator composition, HLB, percentage of the aqueous phase, and addition of the monomer by steps on the final conversion and polyacrylamide molar masses were investigated. High conversions and molar masses were generally obtained with the different formulations. The polyacrylamide molar masses were influenced by the HLB and content in the aqueous phase. The addition of the aqueous phase by steps led to a progressive diminution of the molar masses as the number of stages increased. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 2495–2503, 2005