Analysis of particle formation under monomer-starved conditions in emulsion polymerization reactors

An important characteristic of monomer-starved nucleation in semibatch reactors is that the rate of growth of particles is controlled by the rate of monomer addition. The reduced rate of growth of particles prolongs the nucleation interval by slowing down the rate of emulsifier micelle depletion and forms a larger number of particles (N_p). Model calculations show how N_p varies with the formulation parameters as the monomer-flooded nucleation shifts into monomer-starved one. Particle formation in the intermediate conversion of interval III of the styrene batch emulsion polymerization also showed an enhancement because of a low rate of growth of newly formed particles. However, at a higher conversion, the rate of particle formation decreased significantly. Modeling results show that the reduction in the rate of particle formation at high conversions could not be simply explained by existing theories which rely on the decrease in monomer concentration in the aqueous phase as a means to explain the decrease in the rate of radical capture.     

Particle formation and coagulation in the seeded semibatch emulsion polymerization of butyl acrylate

Particle formation and coagulation in the seeded semibatch emulsion polymerization of butyl acrylate were studied under monomer‐starved conditions. To investigate the importance of the kinetics of the water phase in the nucleation process, the monomer feed rate was used as a variable to alter the monomer concentration in the aqueous phase. The emulsifier concentration in the feed was employed to alter the particle stability. Particle formation and coagulation were discussed in terms of critical surface coverage ratios. Particle coagulation occurred if the particle surface coverage dropped below θ_cr1 = 0.25 ± 0.05. The secondary nucleation occurred above a critical surface coverage of θ_cr2 = 0.55 ± 0.05. The number of particles remained approximately constant if the particle surface coverage was within θ_cr1 = 0.25 < θ < θ_cr2 = 0.55. This surface coverage band is equivalent to the surface tension band of 42.50 ± 5.0 dyne/cm that is required to avoid particle formation and coagulation in the course of polymerization. The kinetics of the water phase was shown to play an important role during homogeneous and micellar nucleations. For any fixed emulsifier concentration in the feed and above θ_cr2, the number of secondary particles increased with monomer concentration in the aqueous phase. Moreover, the presence of micelles in the reaction vessel is not the only perquisite for micellar nucleation to occur, a sufficient amount of monomer should be present in the aqueous phase to enhance the radical capture by partially monomer‐swollen micelles. The rate of polymerization increased with the surfactant concentration in the aqueous phase. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 3612–3630, 2000     

Particle formation in interval III of the emulsion polymerization of styrene with aerosol‐MA as an emulsifier

Particle nucleation in the seeded emulsion polymerization of styrene in the presence of Aerosol‐MA emulsifier micelles and in the absence of monomer droplets (interval III) was investigated. The seed particles were swollen with different amounts of the styrene monomer before the experiments. A larger number of polymer particles formed in interval III than in the corresponding seeded batch operation in the presence of monomer droplets. The increase in the number of particles could be attributed to the reduced rate of growth of new particles, which retarded the depletion of emulsifier micelles. The number of secondary particles initially increased with the initial polymer weight ratio in the seed particles (w_p0) but decreased at a higher range of w_p0, after reaching a maximum at w_p0 = 0.60, and eventually was reduced to zero. At high values of w_p0 (>0.75), polymerization occurred in the seed particles, whereas few or no new particles were formed despite the presence of micelles. The cessation of particle formation at high conversions was ascertained with a semibatch process in which the neat monomer feed was added to the reaction vessel containing the seed particles and emulsifier micelles. For w_p0 > 0.85, the emulsifier micelles were disintegrated to stabilize the seed particles with no secondary particle formation. The possible reasons for the cessation of particle formation at high w_p0 were examined. The size distribution of secondary particles showed a positive skewness in terms of volume because of the declining rate of growth for particles, together with a low rate of growth for small particles. The distribution breadth of new particles sharpened with increasing w_p0. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 1652–1663, 2002     

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     

High solids TEMPO‐mediated radical semibatch emulsion polymerization of styrene

A bicomponent initiation system consisting of 2,2,6,6‐tetramethylpiperidine‐N‐oxyl (TEMPO) and the water soluble initiator potassium persulfate (KPS) was used to develop a robust and versatile semibatch emulsion polymerization process to obtain polystyrene (PS) latexes with solids contents of 5–40 wt %. A window of operating conditions was found that yielded high conversion (>95%) stable latexes and well controlled polymers, overcoming limitations found in previous attempts at developing similar processes using TEMPO. The critical parameters studied were surfactant concentration, monomer concentration in the nucleation step and the monomer feed rate in the semibatch step. Methyl acrylate (MA) was used in the nucleation step to improve the nitroxide efficiency (N_Eff). Latexes having molecular weight distribution (MWD) with dispersity (?) lower than 1.5, average particle size (D_p) from ≈32 to ≈500 nm, nitroxide efficiencies N_Eff up to ≈1.0 and monomer conversions >90% were obtained in less than 12 h with solids contents up to 40 wt %. These results constitute a significant advance over prior efforts in TEMPO‐mediated polymerization in aqueous dispersions. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2016 , 54, 49–62     

On the evolution of the rate of polymerization,number and size distribution of particles in styrene emulsion polymerization above CMC

This work is an extension of a communication reported by two of the authors [Carro and Herrera‐Ordoñez, Macromol Rapid Commun 2006, 27, 274], where bimodal particle size distributions (PSD), obtained by asymmetric flow‐field flow fractionation (AFFF, AF⁴), were taken as evidence of certain degree of stability of primary particles. Now, emulsion polymerizations of styrene were performed under conditions employed before by other researchers, intending to examine if the behavior observed is general. The number of particles (N) and PSD were studied by means of dynamic light scattering and AF⁴. By the later, bimodal PSDs were detected in all cases, where the population corresponding to primary particles (diameter <20 nm) depends on reaction conditions. Regarding N, AF⁴ results show that it is constant during interval II, in contrast to DLS results. Primary particle coagulation was evidenced as minimums in N evolution and the rate of polymerization curves, monitored by calorimetry and gravimetry, which are enhanced when higher particle number is generated and/or the ionic strength is increased. These results suggest that particle coagulation is not as extensive as it would be expected according to the coagulative theory. © 2010 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 3152–3160, 2010     

On-line monitoring,modeling, and model validation of semibatch emulsion polymerization in an automated reactor control facility

The modeling of the semibatch emulsion polymerization of styrene and its validation against data obtained from a reactor facility is presented. The model, which describes the growth of a monodisperse polystyrene seed as neat monomer is fed to the reactor, incorporates recent findings in radical diffusion and kinetics. The current controversy surrounding radical absorption into particles is handled by considering absorption via propagation, diffusion, and collision in the model. Simulation results including weight fraction polymer inside the particles and particle diameter are compared to data obtained from a custom-designed and built automated reactor control facility capable of on-line density and on-line particle diameter measurements. Good agreement between simulation results and experimental data are obtained for any of the three absorption mechanisms considered by varying only one adjustable parameter located in the absorption rate coefficient relation. A sensitivity analysis of the model to this adjustable parameter, using the program ODESSA, is also presented and shown to be an important tool in the validation procedure. Lastly, an analysis of the dynamics of the process shows the variety of phenomena that can be obtained in a semibatch reactor including regions that exhibit pseudosteady states, autoacceleration of the rate, and limiting conversion. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 1553–1571, 1998     

Composition control of copolymer in semibatch emulsion copolymerization. II. MMA/styrene/BMA three‐component system

In this study, polymers of the MMA/Styrene/BMA three‐component system were synthesized through either soapless semibatch emulsion copolymerization or soapless batch emulsion copolymerization technique. The optimal monomer feed flow rate was determined from the interphase partition laws, monomer reactivity ratios, and three or four times of iterative experimental procedures through semibatch emulsion copolymerization. As a result, the instantaneous composition of polymers could also be effectively controlled to get the desired final products. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 3253–3269, 2000     

Stability of the polymerizable surfactant stabilized latex particles during semibatch emulsion polymerization

The effect of the polymerizable surfactant, sodium dodecyl allyl sulfosuccinate (JS-2), on the stability of polybutyl acrylate latex particles during semibatch emulsion polymerization was investigated in this work. Experimental data show that the ionic strength is the most important parameter in determining the latex stability during the reaction. Both the amount of coagulum produced by intensive coagulation and percentage of the particle volume change (ΔV) caused by limited flocculation increase with increasing electrolyte concentration. The parameter Δ V increases significantly when the concentration of JS-2 in the initial reactor charge ([JS-2]_i) increases. The amount of coagulum increases rapidly when the agitation speed is increased from 400 to 800 rpm. Experiments of coagulation kinetics were carried out to study the stability of latex products toward added salts. The experimental data show that the chemical stability of the latex product increases with increasing pH. Furthermore, the critical coagulation concentration and diffuse potential increase with increasing [JS-2]_i. It is postulated that the increasing electrostatic attraction force between two approaching particles due to the increased [JS-2] _i can increase the apparent magnitude of Hamaker constant.     

Preparation of poly(n‐butyl acrylate)‐b‐polystyrene particles by emulsifier‐free,organotellurium‐mediated living radical emulsion polymerization (emulsion TERP)

We have successfully demonstrated the preparation of poly(n‐butyl acrylate)‐b‐polystyrene particles without any coagulation by two‐step emulsifier‐free, organotellurium‐mediated living radical emulsion polymerization (emulsion TERP) using poly(methacrylic acid) (PMAA)–methyltellanyl (TeMe) (PMAA₃₀‐TeMe) (degree of polymerization of PMAA, 30) and 4,4′‐azobis(4‐cyanovaleric acid) (V‐501). The final particle size was ～30 nm and second particle nucleation was not observed throughout the polymerization. M_n increased linearly in both steps with conversion and blocking efficiency was ～75%. PDI was improved by increasing radical entry frequency into each polymer particle due to an increase of the polymerization temperature. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2012     

Kinetics and mechanisms of emulsion polymerization initiated by oil-soluble initiators. IV. Kinetic modeling of unseeded emulsion polymerization of styrene initiated by 2,2′-azobisisobutyronitrile

To explain the kinetic features of particle formation and growth in unseeded emulsion polymerization initiated by oil-soluble initiators, a mathematical kinetic model is proposed, based on the assumption that when initiator radicals or monomer radicals in the water phase enter monomer-solubilized emulsifier micelles, initiate polymerization, and propagate to a chain length which is long enough not to desorb from the micelles, the micelles are regarded to be transformed into polymer particles. It is demonstrated by comparing the experimental results obtained in the emulsion polymerization of styrene initiated by the oil-soluble initiator, 2,2'-azobisisobutyronitrile, with sodium lauryl sulfate as emulsifier that the proposed kinetic model satisfactorily explains the kinetic features such as the effects of initial emulsifier, initiator, and monomer concentrations on both the number of polymer particles produced and the monomer conversion versus time histories. © 1993 John Wiley & Sons, Inc.     

Synthesis of large,high‐solid‐content latexes by miniemulsion polymerization

Multiple and diverse applications have been recently found for miniemulsions and miniemulsion polymerization. In this work, miniemulsion polymerization is presented as a suitable technique for the preparation of high‐solid‐content latices with large particle sizes. Monomer miniemulsions were prepared with a high‐pressure homogenizer, and droplet sizes of 200–700 nm were obtained. Latexes with particle sizes larger than the sizes commonly accepted for miniemulsion polymerization were obtained. With fixed operational conditions of the homogenizer, the type of stabilizer was the key parameter determining the droplet size and the droplet size distribution. The particle size of the latices obtained by miniemulsion polymerization indicated that the particles were mainly formed by droplet nucleation. Latexes obtained by this process have multiple applications, including use as seeds in the polymerization of high‐solid‐content latices. This article shows that potential new applications for miniemulsion polymerization are far from being exhausted. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 4222–4227, 2004     

On the kinetics of styrene emulsion polymerization above CMC. I. A mathematical model

A detailed mathematical model of the kinetics of styrene emulsion polymerization has been proposed. Its main features/assumptions are compartmentalization, micellar and homogeneous nucleation, particle formation by both initiator‐derived and desorbed radicals, dependence on the particle size of the rate coefficients, thermodynamic considerations, and aqueous phase kinetics. The model predicts that micellar nucleation dominates over homogeneous nucleation and that the evolution of the nucleation rate reaches a maximum, where desorbed radicals have an important contribution. Initiator‐derived radicals with only one monomeric unit have also a significant contribution on the rate of capture in particles. The results suggest that the correctness of the instantaneous termination approach depends not only on the size of the particle, but also on the type of entering radical (initiator‐derived or monomeric). © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 2201–2218, 2000     

Oligomer formation in the emulsifier‐free emulsion polymerization of styrene

The formation of oligomers in emulsifier‐free emulsion polymerization of styrene was characterized by means of gel permeation chromatography and surface tension measurements. GPC analysis showed incessant oligomer formation throughout the emulsion polymerization process. Oligomers spanned a molecular weight range of 200–1,500, have an M̄_w of 800–900, an M̄_n of 600–800 and a polydispersity index of 1.3. On average, the oligomers contain 4 to 6 styrene units. UV detection could not be utilized to acquire the weight ratio of oligomers to polymers without correction. Combination was the major mode of termination of free radicals in the aqueous phase, but disproportionation was not negligible: for every three‐combination reactions there was about 1 disproportionation. Surface tension measurements showed that oligomers minimized the surface tension of the latex at about 50 min reaction to only 30 mN/m. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 1323–1336, 2000     

Semicontinuous heterophase polymerization under monomer starved conditions to prepare nanoparticles with narrow size distribution

The semicontinuous polymerization of methyl methacrylate (MMA) in heterogeneous medium under monomer‐starved conditions is reported here. The effect of monomer addition rate on kinetics, particle size, particle number, and PMMA average molar masses are reported. This process permits the synthesis of high‐solid content latexes containing nano‐sized particles (<40 nm) with narrow particle size distributions [(D_w/D_n) < 1.1]. Moreover, the molar masses (M_n ≈ 0.3–1.2 × 10⁶ g/mol) are much lower than those expected by chain transfer to monomer, which is the typical termination mechanism in 0–1 emulsion and microemulsion reactions. Both particle size and average molar masses decrease as the rate of monomer addition is diminished. Possible explanations for this process are provided. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 1463–1473, 2007     

Maximum Achievable Particle Size in Emulsion Polymerization: Modeling of Large Particle Sizes

A simplified model for particle formation in emulsion polymerization (comprising aqueous‐phase propagation to degrees of polymerization which may enter a pre‐existing particle and/or form new particles by homogeneous or micellar nucleation, coupled with the aqueous‐phase and intra‐particle kinetics of oligomeric radicals) is formulated to provide a model suitable for the simulation of systems containing large‐sized particles. The model is particularly useful to explore conditions for growth of large particles while avoiding secondary particle formation. Applied to the Interval II emulsion polymerization of styrene with persulfate initiator at 50°C, it is found that there is an effective maximum particle size that can be achieved if the formation of new particles is to be avoided. The parameter space of initiator concentration, particle number concentration and particle radius is mapped to show a “catastrophe” surface at the onset of new nucleation. Advanced visualization techniques are used to interpret the large number of simulations in the series, showing a maximum achievable particle diameter of around 5 μm.     

Effect of dose rate on emulsion and microemulsion polymerization of styrene

Emulsion and microemulsion polymerization of styrene were initiated with a gamma ray to study the effect of dose rate on polymerization. In both systems, there is an apparent plateau of polymerization rate in the curve of reaction rate vs. conversion. It was shown that emulsion polymerization conformed to the Smith–Ewart theory very well. Changing the dose rate in interval 2 had no great influence on polymerization rate, but it changed the average lifetime of radicals in polymer particles and affected the molecular weight of polymer produced. For microemulsion polymerization it was assumed that in the plateau it is the number of growing polymer particles being kept constant, not the number of polymer particles. When the dose rate was changed while the polymerization came into the constant period, the polymerization rate and the molecular weight of the polymer varied with the dose rate. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 257–262, 1998