“Living” radical polymerization is a relatively new polymerization process that can be used to prepare resins with controlled structures. In this work, a mathematical model developed previously to describe nitroxide‐mediated “living” radical polymerizations performed in tubular reactors is used for the optimization of the process and obtainment of tailor‐made MWDs. Operating conditions and design variables are determined with the help of optimization procedures in order to produce polymers with specified MWDs. It is shown that bimodal and trimodal MWDs, with given peak locations, can be obtained through proper manipulation of the operating conditions. This indicates that the technique discussed in this work is suitable for detailed design of the MWD of the final polymer.
This is the first of a series of works aiming at developing a tool for designing “living” free radical polymerization processes in tubular reactors, in order to achieve tailor‐made MWDs. A mathematical model of the nitroxide‐mediated controlled free radical polymerization is built and implemented to predict the complete MWD. It is shown that this objective may be achieved accurately and efficiently by means of the probability generating function (pgf) transformation. Comparison with experimental data is good. The potential of the resulting model for optimization activities involving the complete MWD is also shown.
Industrial ethylene‐hexene copolymer samples produced using a supported Ti‐based Ziegler‐Natta catalyst were deconvoluted into five Flory molecular weight distributions (MWDs). Relationships between reactor operating conditions and deconvolution parameters confirmed that temperature and hydrogen and hexene concentrations influenced the MWD. The two sites that produced low‐molecular‐weight polymer responded similarly to changes in reactor operating conditions, as did the three sites that produce high‐molecular‐weight polymer. Increasing hexene concentration resulted in relatively more polymer being produced at the two low‐molecular‐weight sites and less at the high‐molecular‐weight sites. The information obtained will be useful for making simplifying assumptions during kinetic model development.
A comprehensive mathematical model for atom transfer radical copolymerization in a batch reactor is presented using the concept of pseudo‐kinetic rate constants and the method of moments. The model describes molecular weight, monomer conversion, polydispersity index, and copolymer composition as a function of polymerization time. Model predictions were compared with experimental data for styrene and butyl acrylate copolymerization and excellent agreement was obtained. We have also tested the model with styrene‐acrylonitrile copolymerization data obtained in our laboratory. Finally, we used the model to study the effect of comonomer reactivity ratio, feed composition, activation and deactivation rate constants on the copolymer composition.
The use of a tubular reactor for conducting living radical polymerizations by atom transfer radical polymerization (ATRP) was investigated. Solution polymerization experiments were performed with styrene and butyl acrylate to elucidate the influence of a continuous reaction process on conversion, molecular weight, and polydispersity compared to batch polymerization experiments. The continuous polymerizations were well controlled. Initial conversion was found to be slightly higher in the tubular reactor than in a batch polymerization run at similar conditions, while number average molecular weight and polydispersity are comparable between the continuous and batch processes. Residence time distribution studies showed the reactor exhibits nearly plug flow behavior.
The use of pressure‐drop and constant‐pressure dilatometry for obtaining rate data for liquid propylene polymerization in filled batch reactors was examined. The first method uses reaction temperature and pressure as well as the compressibility of the reactor contents to calculate the polymerization rate; in the second, the polymerization rate is calculated from the monomer feed rate to the reactor. Estimated polymerization rates compare well to those obtained using the well‐developed isoperibolic calorimetry technique, besides pressure‐drop dilatometry provides more kinetic information during the initial stages of the polymerization than the other methods.
The objective of this paper is to present a dynamic Monte Carlo model that is able to simulate the polymerization of styrene with bifunctional free‐radical initiators in a batch reactor. The model can predict the dynamic evolution of the chain length distribution of polystyrene in the reactor. The model includes all relevant polymerization mechanistic steps, including chemical and thermal radical generation, and diffusion‐controlled termination. The model was applied to styrene polymerization and the Monte Carlo estimates for chain length averages were compared to those obtained with the method of moments. Excellent agreement was obtained between the two methods. Although styrene polymerization was used as a case study, the proposed methodology can be easily extended to any other polymer type made by free‐radical polymerization.
The kinetic behavior of a Ziegler‐Natta catalyst at 86 °C under homopolymerization conditions in a continuous slurry polymerization reactor is studied. The effects of ethylene and hydrogen concentrations on the polymerization rate and polymer properties such as and were investigated. A kinetic model based on two catalytic lumped sites was developed to predict polymerization rate and and from reactor operating conditions. Each lumped site is assumed to be activated instantaneously. Such activation either is spontaneous or requires an ethylene molecule. The model has high fidelity in predicting experimental observations using kinetic parameters estimated from the experimental data and is used for industrial process development, optimization, and new product development.
The molecular weight distribution formed in an ideal reversible addition‐fragmentation chain transfer (RAFT)‐mediated radical polymerization is considered theoretically. In this polymerization, the addition to the RAFT agent is reversible, and the active period on the same chain could be repeated, via the two‐armed intermediate, with probability 1/2. This possible repetition is accounted for by introducing a new concept, the overall active/dormant periods. With this method, the apparent functional form of the molecular weight distribution (MWD) reduces to that proposed for the ideal living radical polymers (Tobita, Macromol. Theory Simul. 2006 , 15, 12). The repetition results in a broader MWD than without the repetition. The formulae for the average molecular weights formed in batch and a continuous stirred tank reactor are also presented.
The viability of a tubular microreactor for the production of polymer dispersions by emulsion polymerization was investigated. The reactor setup and operational conditions necessary to reach a very stable reactor operation were determined. It was found that stability of pre‐emulsion plays a very important role in achieving steady‐state performance. Further, the flow pattern of the microreactor was characterized, observing that the dispersion model can be used because of the effect of the radial molecular diffusion. Finally, a comparative study of the styrene emulsion polymerization in microreactor and batch laboratory reactor was performed. Similar kinetics and properties were achieved, indicating enough mixing in the microreactor.
