Efficiency of mercaptan chain transfer agents in emulsion copolymerizations. I. Influence on kinetics and microstructure. Modeling of radical desorption

The effect of chain transfer agents (CTA) on the emulsion copolymerization of styrene and butyl acrylate was studied in a bench scale 7 L reactor. On-line estimates of conversion were obtained through the joint use of calorimetric measurements and fast gravimetric data. Off-line measurements of partial conversions, molecular weight distribution (MWD), glass transition temperature (T_g), and particle diameter were also performed in order to investigate the effect of two mercaptans (tert-butanethiol and n-dodecanethiol) on both the kinetics of the polymerization process and the microstructure-dependent properties of the copolymer. The obtained experimental results were interpreted in terms of radical desorption and diffusive limitations of the CTA between the oil droplets and the particles. A model has been derived to compute the kinetic constants, the number of radicals per particle, and both the GPC/SEC diagrams and DSC thermograms related to MWD and T_g measurements, respectively. Several batch and semibatch examples are proposed to show that these important variables are satisfactorily fit by the model. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 157–168, 1998     

Semibatch emulsion polymerization of methyl methacrylate using different polyurethane particles

Aqueous acrylic‐polyurethane (AC–PU) hybrid emulsions were prepared by semibatch emulsion polymerization of methyl methacrylate (MMA) in the presence of four polyurethane (PU) dispersions. The PU dispersions were synthesized with isophorone diisocyanate (IPDI), 1000 and 2000 molecular weight (MW) poly(neopentyl) adipate, 1000 MW polytetramethyleneetherglycol, butanediol (BD), and dimethylol propionic acid (DMPA). MMA was added in the monomer emulsion feed. We studied the effect of the use of different PU seed particles on the rate of polymerization, the particle size and distribution, the number of particles, and the average number of radicals per particle. The PU rigidity was controlled by varying the polyol chemical structure, the polyol MW (M_n), and by adding BD. The monomer feed rate was varied to study its influence on the process. It was observed that the PU particles that had been prepared with a higher MW polyol swelled better with MMA before the monomer‐starved conditions occurred. There seemed to be no significant discrepancies between the series with different PU seeds in the monomer‐starved conditions. The overall conversion depended on the monomer addition rate, and the polymerization rate acquired a constant value that was comparable to the value of the monomer addition rate. The instantaneous conversion increased slightly. The average particle size increased, and the total particle number in the reactor was constant and similar to the number of PU particles in the initial charge. The average number of radicals per particle increased. The differences between the system with a constant particle number and average number of radicals per particle and the system with a fixed radical concentration are discussed. The semibatch emulsion polymerization of MMA in the presence of PU particles studied was better compared to the system with a fixed radical concentration. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 844–858, 2005     

Particle formation under monomer‐starved conditions in the semibatch emulsion polymerization of styrene. I. Experimental

Particle formation and particle growth compete in the course of an emulsion polymerization reaction. Any variation in the rate of particle growth, therefore, will result in an opposite effect on the rate of particle formation. The particle formation in a semibatch emulsion polymerization of styrene under monomer‐starved conditions was studied. The semibatch emulsion polymerization reactions were started by the monomer being fed at a low rate to a reaction vessel containing deionized water, an emulsifier, and an initiator. The number of polymer particles increased with a decreasing monomer feed rate. A much larger number of particles (within 1–2 orders of magnitude) than that generally expected from a conventional batch emulsion polymerization was obtained. The results showed a higher dependence of the number of polymer particles on the emulsifier and initiator concentrations compared with that for a batch emulsion polymerization. The size distribution of the particles was characterized by a positive skewness due to the declining rate of the growth of particles during the nucleation stage. A routine for monomer partitioning among the polymer phase, the aqueous phase, and micelles was developed. The results showed that particle formation most likely occurred under monomer‐starved conditions. A small average radical number was obtained because of the formation of a large number of polymer particles, so the kinetics of the system could be explained by a zero–one system. The particle size distribution of the latexes broadened with time as a result of stochastic broadening associated with zero–one systems. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 3940–3952, 2001     

EMULSION POLYMERIZATION IN A SEED-FED CONTINUOUS STIRRED-TANK REACTOR

A numerical method has been developed to predict the particle size distribution (PSD) of the product latex from a steady-state polydisperse-seeded continuous reactor. Simulations have been carried out for the emulsion polymerization of vinyl chloride based on the experimental conditions reported by Berens(l). The simulation results can be reasonably well fitted to the PSD data published by Berens. The radical desorption constant, k_d, for Berens’ vinyl chloride emulsion polymerization can be estimated by fitting the simulated PSD to experimental measurements. The simulation work presented in this article demonstrates that the combination of mathematical modeling and PSD measurements can be a useful tool in studying radical transport rates and aqueous phase termination phenomena. The simulation results also indicate that the continuum diffusion theory for free radical absorption by the particles leads to a better PSD fit than a model based on equal diffusion rates per unit area.     

N‐vinylcaprolactam‐based microgels: Synthesis and characterization

Poly(N‐vinylcaprolactam) (PVCL) is well known for its thermoresponsive behavior in aqueous solutions. PVCL combines useful and important properties; it is biocompatible polymer with the phase transition in the region of physiological temperature (32–38 °C). This combination of properties allows consideration of PVCL as a material for design biomedical devices and use in drug delivery systems. In this work, PVCL based temperature‐sensitive crosslinked particles (microgels) were synthesized in a batch reactor to analyze the effect of the crosslinker, initiator, surfactant, temperature, and VCL concentration on polymerization process and final microgels characteristics. The mean particle diameters at different temperatures and the volume phase‐transition temperature of the final product were analyzed. To obtain information about the inner structure of microgel particles, semicontinuous polymerizations were carried out and the evolution of the hydrodynamic average particle diameters at different temperatures of the microgel synthesized was investigated. In the case of microgel particles obtained in a batch reactor the size and the swelling‐de‐swelling behavior as a function of the temperature of the medium can be tuned by modulating the reaction variables. When the microgel particles were synthesized in a semibatch reactor different swelling‐de‐swelling behaviors were observed depending on particles inner structure. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 2510–2524, 2008     

Model‐based design and synthesis of gradient MMA/tBMA copolymers by computer‐programmed semibatch atom transfer radical copolymerization

Methyl methacrylate (MMA)/tert‐butyl methacrylate (tBMA) gradient copolymers having linear and hyperbolic composition profiles were synthesized. These special copolymer products were achieved via a model‐based computer‐controlled semibatch atom transfer radical copolymerization (ATRcoP) process. A simple ATRcoP model was developed based on the terminal model. The equilibrium constants in the ATRP of MMA and tBMA were estimated by the data correlation. The model was verified by batch experiments and was found to give good correlation for the polymerization rate, molecular weight, and copolymer composition data. The model coupled with a reactor model was then applied to the semibatch ATRcoP and was used to calculate comonomer feeding rates for the targeted gradient composition profiles. It was found that the experimental monomer conversion, molecular weight, and cumulative copolymer composition were in good agreement with their targeted theoretical values. The gradient copolymers had low polydispersities close to 1.1. This work demonstrated the feasibility of the model‐based semibatch ATRcoP in fine‐tuning gradient copolymer composition profiles. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 69–79, 2009     

Unseeded semibatch emulsion polymerization of butyl acrylate: Bimodal particle size distribution

Unseeded semibatch emulsion polymerization of butyl acrylate (BA) using sodium lauryl sulfate as emulsifier and potassium persulfate as initiator was carried out at the conditions where secondary nucleation was probable. This was achieved by using no emulsifier in the initial reactor charge. The effects of changes in monomer emulsion feed rate, initiator concentration and distribution, emulsifier concentration in the feed, and temperature on the evolution of particle size averages and distribution were investigated. Bimodal particle size distributions (PSD) were obtained for most of the latexes. Inhibition effects were found to be important in the development of PSD. Primary particle formation occurred through micellar nucleation, whereas secondary nucleation probably occurred through homogenous nucleation. The polydispersity index (PDI) of the latexes increased with the decreasing monomer emulsion feed rate. The application of a larger amount of initiator to the reactor charge or using a higher temperature, reduced the formation of secondary particles and resulted in a formation of an unimodal PSD. The overall steady‐state rate of polymerization was found to approach the rate of monomer addition (R_p ≈ R_a ), if the emulsifier concentration in the aqueous phase was appreciable. This is different from the correlation 1/R_p = 1/K + 1/R_a obtained for the BA semibatch process with neat monomer feed. This suggests that different rate expressions can be used for BA semibatch emulsion polymerization at different conditions. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 528–545, 2000     

A Monte Carlo Method to Quantify the Effect of Reactor Residence Time Distribution on Polyolefins Made with Heterogeneous Catalysts: Part I—Catalyst/Polymer Particle Size Distribution Effects

Polyolefins are commercially produced in continuous reactors that have a broad residence time distribution (RTD). Most of these polymers are made with heterogeneous catalysts that also have a particle size distribution (PSD). These are totally segregated systems, in which the catalyst/polymer particle can be seen as a microreactor operated in semibatch mode, where the reagents (olefins, hydrogen, etc.) are fed continuously to the catalyst/polymer particle, but no polymer particle can leave. The reactor RTD has a large influence on the PSD of the polymer particles leaving the reactor, as well as in polymer microstructure and properties, polymerization yield, and composition of reactor blends. This article proposes a Monte Carlo model that can describe how particle RTD in a single or a series of reactors can affect the PSD of polymer particles made under a variety of operation conditions. It is believed that this is the most flexible model ever proposed to model this phenomenon, and can be easily modified to track all properties of interest during polyolefin production in continuous reactors with heterogeneous catalysts.     

Kinetics of the batch cationic emulsion polymerization of styrene: A comparative study with the anionic case

An in‐depth study on the kinetics of the cationic emulsion polymerization of styrene in a batch reactor is presented. This study is focused on the effect of the amount of the cationic surfactant dodecyltrimethylammonium bromide (DTAB), using two different cationic initiators: 2,2′‐azobisisobutyramidine dihydrochloride (AIBA), 2,2′‐azobis (N,N′‐dimethyleneisobutyramidine) dihydrochloride (ADIBA), on kinetics and colloidal features such as conversion, number of particles, number average of radicals per particle, mean particle diameter, and particle size distribution (PSD) of the polystyrene latices obtained by emulsion polymerization in a batch reactor. Furthermore, the results of the cationic emulsion polymerization were compared with its homologous anionic case. Using DTAB as cationic surfactant an expected increase in the total rate of polymerization was observed when the DTAB concentration increased. However, the total number of particles increased much more than in the anionic system. On the other hand, a dependence on the particle size of the rate of polymerization per particle together with the average number of radicals per particle was found. These differences between cationic and anionic emulsion polymerizations were explained taking into account the limited particle coagulation observed with cationic surfactants, and the high rate of radical formation of cationic initiators. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 4461–4478, 2006     

Nanoparticle formation by monomer-starved semibatch emulsion polymerization

Latexes with very small particle size are usually manufactured by microemulsion polymerization. This article explains the preparation of nanolatexes by monomer-starved nucleation in a conventional semibatch emulsion polymerization with a low surfactant/monomer ratio and with no need for a cosurfactant. The semibatch emulsion polymerization reactions started with an aqueous solution of a surfactant and a water soluble initiator. Monomer was added at a fixed rate. The size of particles decreased with decreasing rate of monomer addition. High solids content nanolatexes with particles as small as 25 nm in diameter were produced. Several monomers with different water solubilities were compared. The order of the number of particles in terms of the rate of monomer addition was found to depend on the type of monomer. Water soluble monomers produced more particles due to associated chain transfer to monomer and radical exit. The monodispersity of particles at the end of nucleation increased as the rate of monomer addition decreased. The technique seems to be preferable to microemulsion polymerization, which uses a high concentration of surfactant/cosurfactant and is limited to low monomer holdup.     

钾促进的Co-Mn-Al混合氧化物催化剂上模拟废气中N2O的分解减排

Intrinsic data of N2O catalytic decomposition over a K-promoted Co-Mn-Al mixed oxide prepared by the thermal treatment of a layered double hydroxide was used for the design of a pilot reactor for the abatement of N2O emissions from the off-gases in HNO3 production.A pseudo-homogeneous one-dimensional model of an ideal plug flow reactor under an isothermal regime(450°C)was used for reactor design.A catalyst particle diameter of 3 mm is a compromise size because increasing the size of the catalyst particle leads to a decrease in the reaction rate because of an internal diffusion limitation,and particles with a smaller diameter cause a large pressure drop.A catalyst bed of 11.5 m 3 was estimated for the target N2O conversion of 90%upon the treatment of 30000 m 3 /h of exhaust gas(0.1 mol%N2O,0.005 mol% NO,0.9 mol%H2O,5 mol%O2)at 450°C and 130 kPa.     

Optimization of post-column reactor radius in capillary high performance liquid chromatography Effect of chromatographic column diameter and particle diameter

A post-column reactor consisting of a simple open tube (Capillary Taylor Reactor) affects the performance of a capillary LC in two ways: stealing pressure from the column and adding band spreading. The former is a problem for very small radius reactors, while the latter shows itself for large reactor diameters. We derived an equation that defines the observed number of theoretical plates (N(obs)) taking into account the two effects stated above. Making some assumptions and asserting certain conditions led to a final equation with a limited number of variables, namely chromatographic column radius, reactor radius and chromatographic particle diameter. The assumptions and conditions are that the van Deemter equation applies, the mass transfer limitation is for intraparticle diffusion in spherical particles, the velocity is at the optimum, the analyte's retention factor, k', is zero, the post-column reactor is only long enough to allow complete mixing of reagents and analytes and the maximum operating pressure of the pumping system is used. Optimal ranges of the reactor radius (a(r)) are obtained by comparing the number of observed theoretical plates (and theoretical plates per time) with and without a reactor. Results show that the acceptable reactor radii depend on column diameter, particle diameter, and maximum available pressure. Optimal ranges of a(r) become narrower as column diameter increases, particle diameter decreases or the maximum pressure is decreased. When the available pressure is 4000 psi, a Capillary Taylor Reactor with 12 microm radius is suitable for all columns smaller than 150 microm (radius) packed with 2-5 microm particles. For 1 microm packing particles, only columns smaller than 42.5 microm (radius) can be used and the reactor radius needs to be 5 microm.     

Core–shell and gradient morphology polymer particles analyzed by X‐ray photoelectron spectroscopy: Effect of monomer feed order

The synthesis of composite latex particles possessing core–shell and gradient morphologies, respectively, using seeded starve‐fed semibatch emulsion polymerization of styrene (St) and methyl methacrylate (MMA) is presented. The focus is on the effect of the monomer feed order on the particle morphology development. The particle morphology is assessed using a novel approach which entails comparing the experimental surface composition as a function of polymerization time (particle growth) obtained by X‐ray photoelectron spectroscopy with the predicted surface composition using a mass balance mathematical model. Both types of composite latexes (core–shell and gradient) feature changes with polymerization time in the oxygen/carbon surface composition which enables one to track the morphology development. Differential scanning calorimetry is also implemented to analyze the extent of phase separation. The monomer feed order is shown to play a crucial role—under the present conditions, gradient and core–shell particles are obtained if the feed order is St/MMA (St fed first), but not if the feed order is reversed. These findings illustrate that thermodynamic factors are important, given that thermodynamically it is more favorable for MMA‐rich chains to occupy the oil–water interface to reduce the interfacial tension. Systems where St is the second stage monomer lead to mixed structures rather than the targeted core–shell or gradient morphology with St‐rich chains at the particle surface. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 2513–2526     

Particle nucleation in emulsion polymerization. I. A theory for homogeneous nucleation

This paper is the first in a series intended to clarify the particle nucleation mechanisms in emulsion polymerization. The theory for particle nucleation by precipitation of oligomeric radicals from the water phase is discussed and a model based on the diffusion, propagation and termination steps is presented. The physical factors that influence the capture rate of oligomers in particles are discussed, and qualitative expressions for the electrostatic repulsion and reversible diffusion are derived. These factors are shown to be able to explain the relatively slow absorption rate of oligomers in particles and micelles. A kinetic model for simultaneous particle nucleation and limited flocculation is presented. Numerical integration of this model shows that the particle number goes through a maximum and that simultaneous nucleation and flocculation of primary particles may take place after Interval I in an emulsion polymerization is finished.     

Tailored bimodal ultra‐high molecular weight polyethylene particles

A single molecular catalyst system supported on MgCl₂ has been developed and combined with a simple two‐stage fed‐batch polymerization process to produce tailored bimodal polyethylene reactor blend particles of UHMWPE. By varying and controlling the process conditions in the first stage and second stage, bimodal HMWPE:UHMWPE reactor particles are obtained with independent control over the individual molar masses, the mass ratio of the HMWPE and UHMWPE components, and the reactor powder particle size. This allows multidimensional control over the individual UHMWPE reactor particle properties. © 2018 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2018 , 56, 1645–1656     

Rapid spectroscopic confirmation of the presence of polystyrene in polymer particles of mixed composition

A technique for rapid determination of the presence of polystyrene in individual micron-diameter polymer particles of mixed composition is presented. This technique is based upon observation of visible emission from conjugated regions of the polymer backbone, generated photochemically, while the particle is held in an optical trap. Particle emission characteristics are dependent upon particle size and suspending solvent. Emission spectra are provided for single component polystyrene particles and mixed polymer particles containing poly(methyl methacrylate), poly(N-vinyl pyrrolidone), and polystyrene. © 1998 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 36: 999–1004, 1998     

Particle formation mechanism and kinetic model of ultrasonically initiated emulsion polymerization

A general kinetic model of particle formation in an ultrasonically initiated emulsion polymerization system is presented. This model takes into account homogeneous, micelle entry, and monomer droplet nucleation mechanism. The effects of the ultrasound in producing free radical, degrading free radical and influencing the fashion of the nucleation are also considered. Moreover, chain transfer to monomer and termination in the aqueous phase, capture of oligomer radicals by particles, and coagulation of particles are also considered. An analytical solution is obtained for the initial particle stage consideration. This model predicts that, if the desorption of radical from particles can be neglected, the concentration of the total radical in the aqueous phase is directly proportional to the cavitation concentration. Model predictions are in good agreement with experimental data obtained from the literature.     

Methyl methacrylate emulsion polymerization at low monomer concentration: Kinetic modeling of nucleation,particle size distribution,and rate of polymerization

The results of a mathematical model developed in the authors' previous work are discussed and compared against final number (N) and size distribution of particles (PSD) and the rate of polymerization (RP) experimental data of methyl methacrylate (MMA) emulsion polymerization above the critical micelle concentration (cmc) of the surfactant. On the basis of the model results, the hypothesis that the observed bimodal PSD can be ascribed to secondary nucleation as proposed in the literature is questionable. It is discussed that this PSD can also be caused by differences in the growing rate of different‐size particles as predicted for styrene emulsion polymerization. Because of the small particle size obtained at low initial monomer concentration, the high rate of free‐radical desorption reduces the accumulation of these species; therefore, the autoacceleration effect is less pronounced for the conditions under study compared with the usual behavior of the RP during MMA emulsion polymerization above cmc. Similarities and differences between model predictions and experimental data are discussed. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 2547–2556, 2001     

Particle nucleation in emulsion polymerization. III. Nucleation in systems with anionic emulsifier investigated by seeded and unseeded polymerization

Studies of seeded and unseeded polymerization of styrene using sodium dodecylsulfate as emulsifier have been carried out in order to investigate the mechanism of particle nucleation in such systems and to test the theory presented in Part I of this series. The rate of capture of water-soluble oligomeric radicals was considered to be governed by absorption of oligomers with chain length one less than the critical chain length. It was concluded that the micelles became the dominating loci for particle nucleation above CMC for the emulsifier. A complete nonsteady-state model for particle initiation above CMC which takes into account radical desorption and reabsorption has been developed. It was indicated that, even for styrene, desorption of radicals may play a role in controlling the radical and particle number of interval I under certain conditions. The model also showed that the efficiencies of particles in absorbing radicals could be calculated from physical parameters, such as diffusion constants and surface charge densities, which are available for the system.