Distribution of polymer deposition in plasma polymerization. I. Acetylene,ethylene, and the effect of carrier gas

Factors which influence the distribution of polymer deposition in an electrodeless glow-discharge system were investigated for acetylene and ethylene. Under the conditions in which “full glow” is maintained, the distribution of polymer deposition from pure monomer flow systems is nearly independent of flow rate of monomer or of the system pressure in discharge, but is largely determined by the characteristic (absolute) polymerization rates (not deposition rate) of the monomers. Acetylene has a high tendency to deposit polymer near the monomer inlet, whereas ethylene deposits polymer more uniformly in wider areas in the reactor. The addition of carrier gas such as argon or partially copolymerizing gas such as N₂, H₂, and CCl₂F₂ was found to narrow the distribution of polymer deposition. The distribution of polymer deposition is also influenced by a glow characteristic which is dependent on flow rate and discharge power.     

反应器型式对甲烷低温等离子体转化制C2烃的影响

就不同反应器对甲烷常压低温等离子体转化制C2烃的影响进行了研究。结果表明,相同的甲烷停留时间和相同甲烷流率下,反应器A和B中反应的主要产物是乙炔,乙烯和乙烷的含量较少,积炭量较多;而反应器C和D中反应的主要产物为乙烷和丙烷,乙烯和乙炔含量较少,积炭量很少。反应积炭对反应器A中甲烷转化率影响很大,对于产物选择性影响不大,而对反应器C中的反应影响较小。根据产物分布可知,在反应器A和B中,由于电子具有很高的能量和密度,甲烷主要解离为碳原子;而在反应器C及D中,由于电子能量和密度较低,甲烷主要解离为CH3自由基。     

Effects of Reaction Conditions on the Plasma Polymerization of Ethylene

Abstract

Ehylene can be polymerized at low pressures in a radio-frequency glow discharge. The form of the resulting polymer may be a powder at low pressure (1 to 2 Torr) and low monomer feed rate (10 to 40 cc/min), a colorless film at low pressure and high feed rate (70 to 90 cc/min), or an oil at high pressure (4 to 5 Torr) and high feed rate. The powder and film forms of plasma-polymerized ethylene are insoluble in common organic solvents, indicating a highly cross-linked structure. The oily products, however, are soluble in acetone and xylene. Chemical evidence indicates that the oil is most likely composed of highly branched oligomers of ethylene. Mass spectrometric analysis of the gaseous effluents show that under film-forming conditions the only hydrocarbon species observable are those derived from ethylene. The powder- and oil-forming conditions, on the other hand, yielded oligomeric species. On the basis of this evidence, a mechanism for the plasma-polymerization of ethylene is proposed.     

油浆高温快速裂解过程的气固相产物研究

采用高频炉快速热解装置研究油浆的高温快速热解特性,考察了热解温度、氮气流量对气固相产物的组成和产率的影响。温度是影响气相产物产率的关键因素,气相产物主要为甲烷、氢气和乙烯,升高温度可提高甲烷和氢气的产率,而乙烯产率受高温下二次反应的影响在800℃到达最大值后逐渐降低,乙烷、丙烯产率较小且受二次反应的影响在700℃到达最大值后逐渐降低,温度高于800℃时会有少量乙炔生成且升温可提高乙炔产率。增加氮气流量可降低甲烷、氢气分压,缩短乙烯、丙烯等在高温区的停留时间,从而增加气相产物的产率。积炭产率随热解温度升高迅速增加,氮气流量的增加能够削弱二次反应从而降低积炭产率。     

Fundamentals of Plasma Polymerization

The plasma polymerization of ethylene is used as an example through which to discuss the elementary steps involved in forming a polymer in an electric discharge. The relationship of the experimentally controlled variables to the rate of formation of first generation active species is discussed. These species are related, in turn, to the overall rate of polymerization through a simple model. Two asymptotic conditions are discussed which correspond to minimal and total conversion of monomer to polymer. The dependence of polymer deposition rate on monomer flow rate predicted by the model is found to correspond very closely to that observed experimentally. The predicted effect of gas pressure on polymer deposition rate also agrees with that found experimentally.     

Distribution of polymer deposition in plasma polymerization. II. Effect of reactor design

The effects of relative positions of the monomer inlet and the r.f. coil, and of the inlet and outlet, on the distribution of polymer deposition in plasma polymerization of ethylene were investigated using an electrodeless glow discharge by a 13.5-MHz radiofrequency source. The diffusional transport of active species created under the r.f. coil, diffusional transport of polymer forming species, and flow of gas in the system are important factors that determine the distributions of polymer deposition observed in plasma polymerization of ethylene. The mechanisms of polymer deposition are discussed in conjunction with postulated plasma polymerization mechanisms.     

IR laser ablative decomposition and depolymerisation/repolymerisation of poly(ethylene succinate)

Pulsed IR laser ablation of poly(ethylene succinate) results in the formation of volatile products (mainly carbon oxides, hydrogen, C₁-C₄ hydrocarbons) and affords deposition of polymeric films. Composition, structure and molecular weight distribution of the latter products were examined by EDX-SEM, FTIR, UV and NMR spectroscopy and gel permeation chromatography and revealed to be virtually identical to the initial poly(ethylene succinate). The deposited films and poly(ethylene succinate) decompose in the same way, as proved by TGA analysis. The formation of the volatile products is accounted for by random cleavages of the polymer backbone. The deposition of the polymeric products is judged to be due to molecular ester group interchange and/or a sequence of the C-C bond homolysis and recombination of the produced radicals.     

Reactions in a Mixture of CH_4 and CO_2 under the Action of Microwave Discharge at Atmospheric Pressure

Reactions between CH_4 and CO_2 under the action of continuous microwave discharge at atmospheric pressure were studied in a special homemade reactor. The main products were CO and H2, while acetylene and ethylene were also found in the products. Experimental results show that conversions of CH4 and CO2 could be higher than 90% without the presence of any catalyst. Effects of CO2/CH4 molar ratio and total flow rate of the feed gas on the reaction were also investigated.     

Reactions in a Mixture of CH4 and CO2 under the Action of Microwave Discharge at Atmospheric Pressure

Reactions between CH4 and CO2 under the action of continuous microwave discharge atatmospheric pressure were studied in a special homemade reactor. The main products were CO and H2,while acetylene and ethylene were also found in the products. Experimental results show that conversionsof CH4 and CO2 could be higher than 90% without the presence of any catalyst. Effects of CO2/CH4molar ratio and total flow rate of the feed gas on the reaction were also investigated.     

Reactions in a Mixture of CH4 and CO2 under the Aciton of Microwave Discharge at Atmospheric Pressure

Reactions between CH4 and CO2 under the action of continuous microwave discharge at atmospheric pressure were studied in a special homemade reactor,The main products were CO and H2,while acetylene and ethylene were also found in the products.Experimental results show that conversions of CH4 and CO2 could be higher than 90% without the presence of any catalyst,Effects of CO2/CH4 molar ratio and total flow rate of the feed gas on the reaction were also investigated.     

Influence of Helium on the Conversion of Methane and Carbon dioxide in a Dielectric Barrier Discharge

We have studied the production of synthesis gas and other hydrocarbons in a dielectric barrier discharge using mixtures of helium, methane and carbon dioxide. It was found that helium has a significant influence on the discharge, decreasing the breakdown voltage and increasing the rate of conversion of CH₄ and CO₂. However it also decreases the selectivities and the range of stable operating conditions for the discharge. The main products obtained were H₂, CO, C₂H₆ and C₃H₈ but traces of other hydrocarbon, carbon deposition and the formation of condensable products were also detected. The rate of conversion and conversion abilities were obtained by fitting the conversion results to a model.     

乙烯在煤焦及石英砂床层上裂解实验研究

以石油炼制过程中产生的炼厂气与煤共转化利用为背景,采用小型石英管固定床反应装置,在850℃～1000℃下,对乙烯在空床、彬县煤焦以及石英砂床层上的裂解反应进行了研究。结果表明,乙烯裂解产物包括氢气、甲烷、乙烷及裂解炭,反应温度越高,裂解越彻底,生成的氢气越多;850℃～950℃时,乙烯在彬县焦上初始转化率最高,随着反应的进行逐渐降低到一个较低的平衡值,并且与在石英砂上裂解结果接近。这说明新鲜彬县煤焦对乙烯裂解呈现良好的催化作用,但随着反应进行其催化活性由于裂解生成的炭沉积在煤焦表面而逐渐丧失。1000℃时乙烯在石英砂上和空床裂解转化率均可达到94％,即在此温度下乙烯无需催化剂通过热作用即可接近完全裂解。     

Kinetic Features of Initiation of Poly(ethylene terephthalate) Oxidative Degradation Processes in Oxygen Plasma

The results of measurements of time dependences for the formation rates of gaseous products and oxygen uptake rate in oxygen plasma treatment of a poly(ethylene terephthalate) film at discharge currents of 20–80 mA and a pressure ranging within 50–200 Pa are reported. The obtained data allow the authors to speculate on the mechanism of initiation of plasma-induced oxidative degradation of the material.     

Surface State of a Silver Catalyst for Ethylene Glycol Oxidation

The surface state of electrolytic silver before and after treatment with a reaction mixture in the course of ethylene glycol oxidation to glyoxal was studied using X-ray photoelectron spectroscopy and scanning electron microscopy. It was found that electrophilic forms of adsorbed oxygen, which participate in the selective conversion of ethylene glycol, were formed on the surface of electrolytic silver crystals under exposure to oxygen under conditions similar to catalytic process conditions. The treatment of the catalyst with a reaction mixture resulted in the formation of filamentous carbon deposition products. A mechanism of formation of carbon-containing products was proposed.     

In situ FTIR investigation of MMA plasmas,plasma-polymerized films,and reaction mechanisms

Methyl methacrylate (MMA) plasmas and plasma-polymerized methyl methacrylate (PPMMA) films were studied in situ with FTIR and FTIR/ATR (attenuated total reflection) in an r.f. capacitively coupled glow discharge. A statistically designed experiment was conducted by varying the r.f. power, process pressure, and MMA flow rate. MMA plasma fragments were identified from the gas-phase FTIR measurements. They include the intermediate species such as dimethylketene, formaldehyde, allene, and propene; small hydrocarbons such as acetylene, methane, and ethylene; and oxygenates such as carbon dioxide, carbon monoxide, and methanol. Statistical analysis techniques (correlation analysis, analysis of variance and regression analysis) were used on both gas and film data. Gas-phase reaction mechanisms are proposed, and the relationship between the gas and film data is investigated to understand the film deposition chemistry. The deposition rate is positively correlated to the relative concentrations of MMA fragments which are identified as the major film precursors in the deposition process. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 587–602, 1998     

The Role of Halogens in the Plasma Polymerization of Hydrocarbons

Vinyl chloride, vinyl fluoride, and tetrafluoroethylene were polymerized in a radio frequency electric glow discharge. It was found that when compared with the unhalogenated simple hydrocarbons, the rates of polymer deposition are in the order vinyl chloride, acetylene, tetrafluoroethylene, vinyl fluoride, ethylene. This observation can be rationalized by considering the ease with which free radical and unsaturated species can be formed in the plasma. IR spectra show that the structures of plasma-polymerized vinyl chloride and vinyl fluoride are in many respects similar to the plasma-polymerized hydrocarbon. The spectrum of plasma-polymerized tetrafluoroethylene, however, does not resemble that of conventional polytetrafluoroethylene. Addition of dichlorodifluoromethane to the monomer stream dramatically increased the polymer deposition rate; the effect is more subdued for chloromethane and is negligible for tetrafluoromethane. Elemental analysis indicates that little of the added halogens is present in the resultant polymers. Thus the halogenated compounds appear to act as a gas phase catalyst for the plasma polymerization of hydrocarbons.     

A Global Model of Chemical Vapor Deposition of Silicon Dioxide by Direct-Current Corona Discharges in Dry Air Containing Octamethylcyclotetrasiloxane Vapor

A model of the electron distribution in direct current corona plasmas is combined with a global chemistry model and a two-dimensional transport model to predict the rate of chemical vapor deposition of silicon dioxide on the discharge wire in both positive and negative discharges in dry air containing octamethylcyclotetrasiloxane. The gas-phase chemistry includes reactions to form atomic oxygen (O) and additional global reactions to form gaseous silicon dioxide precursors by the impact reactions of electrons and atomic oxygen with silicone molecules. Surface chemistry is approximated by a single step global reaction from gaseous to solid silicon dioxide. The rate coefficient between atomic oxygen and octamethylcyclotetrasiloxane is estimated from prior experiments to be on the order of 10^–12 cm³/molecule-s. The effects of discharge polarity, current, wire radius and air velocity (Peclet number for mass transfer) on the deposition rate are considered. Deposition rates can be minimized by using positive coronas instead of negative coronas for Peclet number less than 18.5. At higher Peclet numbers, the deposition rate is slightly higher in positive corona discharges, but devices used indoors should continue to use the positive corona in order to minimize the production of ozone. The deposition rate in the positive corona is relatively insensitive to air velocity for velocities from 0.044 to 10 m/s^–1 . However,it may be minimized by operating the corona with the lowest current that provides adequate performance (e.g., particle charging) and the smallest wire that provides adequate mechanical strength.     

Plasma polymerization of tetrafluoroethylene. IV. Comparison of ethylene and tetrafluoroethylene by measurement of electron temperature and density of positive ions

The double probe method was applied to plasma of tetrafluoroethylene (TFE) and ethylene and the electron temperature (T_e) and density of positive ions (n_p) were measured at various discharge wattages. The probe current-probe voltage diagrams for TFE were different from those for ethylene. The shape of its diagram indicates that a considerable number of negative ions exist in TFE plasma. The levels of n_p for TFE were also nearly six times greater than those for ethylene at the same discharge current. The dependence of TFE polymer deposition and the chemical structure of the polymer, based on ESCA data on discharge current, was related to T_e and n_p measured by the probe method. The values of T_e and n_p may not be directly related to the polymer formation in a plasma; the method provides a direct measure of plasma energy density where plasma polymerization takes place, whereas it cannot be accurately estimated by the input energy of a discharge. It was found that plasma energy density based on (n_pT_e) for TFE plasma and that for ethylene differ significantly at the same level of input parameter (W/FM), where W is the discharge wattage, F is the volume flow rate, and M is the molecular weight of the monomer.     

Depolymerisation of poly(ethylene terephthalate) fibre wastes using ethylene glycol

Poly(ethylene terephthalate) [PET] fibre wastes from an industrial manufacturer was depolymerised using excess ethylene glycol [EG] in the presence of metal acetate as a transesterification catalyst. The glycolysis reactions were carried out at the boiling point of ethylene glycol under nitrogen atmosphere up to 10 h. Influences of the reaction time, volume of EG, catalysts and their concentrations on the yield of the glycolysis products were investigated. The glycolysis products were analysed for hydroxyl and acid values and identified by different techniques, such as HPLC, ¹H NMR and ¹³C NMR, mass spectra, and DSC. It was found that the glycolysis products consist mainly of bis(hydroxyethyl)terephthalate [BHET] monomer (>75%) which was effectively separated from dimer in quite pure crystalline form.     

Relative rates for plasma homo- and copolymerizations of olefins in a homologous series of fluorinated ethylenes

It is well known that the rate of plasma polymerization, or deposition rate, of a given monomer depends on various plasma process parameters, e.g., monomer flow rate, pressure, power, frequency (DC, rf or microwave), location of the substrate in the reactor, reactor geometry or configuration, and temperature. In contrast, little work has been done to relate deposition rates to monomer structures for a homologous series of monomers where the rates are obtained under identical plasma process parameters. For the particular series of fluorinated ethylenes (C2HxF4-x; x = 0-4), deposition rates were reported for ethylene (ET), vinyl fluoride, vinylidene fluoride and tetrafluoroethylene (TFE), but for plasma polymerizations carried out under different discharge conditions, e.g., pressure, current density, and electrode temperature. Apparently, relative deposition rates were reported for only two members of that series (ET, x = 4, and TFE, x = 0) for which the plasma polymerizations were conducted under identical conditions. We now present relative deposition rates for both homopolymerizations and copolymerizations of the entire series of fluorinated ethylenes (x = 0-4). Our interest in such rates stems from prior work on the plasma copolymerization of ET and TFE in which it was found that the deposition rates for the plasma copolymers, when plotted versus mol % TFE in the ET/TFE feed stock, followed a concave-downward curve situated above the straight line joining the deposition rates for the plasma homopolymers. This type of plot (observed also for an argon-ET/TFE plasma copolymerization) indicated a positive interaction between ET and TFE such that each monomer apparently "sensitized" the plasma copolymerization of the other. Since the shape of that plot is not altered if mol % TFE is replaced by F/C, the fluorine-to-carbon ratio, this paper aims (1) to show how the relative deposition rates for plasma copolymers drawn from all pairs of monomers in the C2HxF4-x series, as well as the deposition rates for the individual plasma homopolymers, vary with F/C ratios of the monomers or monomer blends, and (2) to see if those rates give rise to a common plot.