Model Reduction in Emulsion Polymerization Using Hybrid First Principles/Artificial Neural Networks Models, 2

Summary: A “series” hybrid model based on material balances and artificial neural networks to predict the evolution of weight average molecular weight, , in semicontinuous emulsion polymerization with long chain branching kinetics is presented. The core of the model is composed by two artificial neural networks (ANNs) that calculate polymerization rate, R_p, and instantaneous weight‐average molecular weight, from reactor process variables. The subsequent integration of the material balances allowed to obtain the time evolution of conversion and , along the polymerization process. The accuracy of the proposed model under a wide range of conditions was assessed. The low computer‐time load makes the hybrid model suitable for optimization strategies.

Effect of the monomer feed rate on .     

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     

Continuous Reactor Concepts with Superimposed Secondary Flow – Polymerization Process Intensification

Different unconventional continuous polymerization reactor concepts with superimposed secondary flow are presented. Exemplary polymerization reactions and the residence time distributions are discussed. In the case of the Taylor reactor polymerization process intensification is demonstrated by examples of emulsion and micro-emulsion polymerization which actually results in an increase in space time yield of up to a factor of 50.     

Emulsion polymerization of styrene. I. Review of experimental data and digital simulation

Isothermal emulsion polymerization at 60°C of styrene in a batch reactor were studied by using sodium lauryl sulfate as surfactant and potassium persulfate as initiator source. The concentrations of surfactant and initiator were varied during the runs. The polymerization evolution was followed as samples were taken at regular intervals. These emulsion samples were analyzed for monomer conversion, rate of polymerization, as well as for the size and the size distribution of the particles. The molecular weight and molecular weight distribution were obtained by gel permeation chromatography. Our study showed that fresh nucleation takes place even at high conversion, causing a continuous shifting toward broadening of particle size distribution. Contrary to the theory of Smith and Ewart, which assumes a constant number of particles during interval II of the polymerization reaction, our digital simulation of the reaction presents better experimental results with a variable number of particles, and indicates that the Hui–Hamielec model for termination constant k_t as function of conversion is not applicable under our working conditions.     

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     

Photoinitiated,inverse emulsion polymerization of acrylamide: Some mechanistic and kinetic aspects

The kinetics of photoinitiated, inverse emulsion polymerization of acrylamide with 2,2‐dimethoxy‐2‐phenylacetophenone (DMPA) as a photoinitiator was investigated under three different cases. First, in a quartz reactor transparent to full UV light, the polymerization rate (R_p) increased and then decreased with the change of initiator order from 0.27 to a negative value when the DMPA concentration was increased, and it was particularly unusual that monomer orders at different DMPA concentrations were lower than the first. Second, for polymerization without DMPA in a quartz reactor, the dependence of R_p on monomer concentration was similar to that of R_p on initiator concentration in the aforementioned case. Third, when polymerization was carried out in a Pyrex reactor where the far UV light was filtered, a peak rate was also observed, and initiator orders varied from 0.24 to a negative value; however, under this case monomer orders at different initiator concentrations were greater than the first. These results indicated that the effect of absorbance often observed in bulk or solution photopolymerization also existed in this system, and the self‐initiation of monomer had some influence on polymerization, and the role of primary radical termination could not be neglected, as evidenced by kinetic analysis. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 846–852, 2004     

Ab initio Emulsion Polymerization by RAFT (Reversible Addition–Fragmentation Chain Transfer) through the Addition of Cyclodextrins

A novel process to produce homo‐ and copolymers by RAFT polymerization in emulsion is presented. It is known that RAFT‐controlled radical polymerization can be conducted in emulsion polymerization without disturbing the radical segregation characteristic of this process, thus leading to polymerization rates identical to those encountered in the corresponding nonliving systems. However, RAFT agents are often characterized by very low water solubility and, therefore, they diffuse very slowly from the monomer droplets, where they are initially solubilized, to the reaction loci, i.e., the polymer particles. Accordingly, when used in emulsion polymerization, they are practically excluded from the reaction. In this work, we show that cyclodextrins, well‐known for their ability to form water‐soluble complexes with hydrophobic molecules, facilitate the transport across the H₂O phase of the RAFT agent to the polymer particles. Accordingly, chains grow through the entire process in a controlled way. This leads to the production of low‐polydispersity polymers with well‐defined structure and end functionalities as well as to the possibility of synthesizing block copolymers by a radical mechanism.     

Preparation of a xanthate‐terminated dextran by click chemistry: Application to the synthesis of polysaccharide‐coated nanoparticles via surfactant‐free ab initio emulsion polymerization of vinyl acetate

Stable monodisperse poly(vinyl acetate) (PVAc) submicronic latex particles were synthesized by ab initio batch emulsion polymerization using a dextran derivative from renewable resource as an efficient steric stabilizer. The dextranend‐functionalized by a xanthate moiety was synthesized by Huisgen's 1,3‐dipolar cycloaddition (click chemistry). It was applied as a macromolecular RAFT (reversible addition fragmentation chain transfer) agent in surfactant‐free emulsion polymerization of vinyl acetate to form in situ an amphiphilic block copolymer able to efficiently stabilize the latex particles. The method afforded the preparation of high solids content (27%) latices coated by dextran. Both the kinetic study and the molar mass analyses confirmed the involvement of the dithiocarbonate group in the emulsion polymerization process. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 2845–2857, 2008     

Effect of reaction medium on copolymerization of acrylonitrile and methyl acrylate

The copolymerization of acrylonitrile (AN) with methyl acrylate (MEA) has been investigated in three types of polymerization, i.e., emulsion polymerization in water with a water-soluble initiator, suspension polymerization in water with an oil-soluble and water-insoluble initiator, and solution polymerization in dimethyl sulfoxide (DMSO). Monomer reactivity ratios at 50°C. for AN and MEA are found to be r₁ = 0.78 ± 0.02, r₂ = 1.04 ± 0.02 in emulsion polymerization; r₁ = 1.02 ± 0.02, r₂ = 0.70 ± 0.02 in DMSO solution polymerization; r₁ = 0.75 ± 0.05, r₂ = 1.54 ± 0.05 in suspension polymerization. The large differences found in the reactivity ratios may be attributed to the different ratio of concentration of two monomers in the loci of polymerization. Chemically, AN is somewhat more reactive than MEA as shown by the reactivity ratios in DMSO. In the case of the suspension polymerization, the MEA/AN ratio in the polymer particles in which polymerization occurs may be higher than that in the total phase. Experimental results of the emulsion polymerization show that the emulsion polymerization of AN occurs both in the particles and in water. In addition, rates of the copolymerization of AN with MEA have also been investigated.     

Emulsion polymerization: On the characterization of the particle size distribution

In emulsion polymerization, the polymer particles generated exhibit a size distribution. Broadness of the distribution is usually characterized by the uniformity (D_p), a ratio of weight to number average particle sizes, and is found to decrease with reaction time despite the fact that the particle volume distribution is usually broadened. Based on the mathematical model proposed by Lichti, Gilbert, and Napper, detailed analysis using the method of moment shows that standard deviation of the particle volume distribution increases with time, while that of the particle diameter distribution decreases with time. D_p's of both volume and diameter distributions all show decreasing with reaction time. These results are in agreement with those found experimentally. The present analysis indicates that, in the characterization of the broadness of the PSD in the emulsion polymerization, one has to be aware of the difference in meanings among these parameters related to the broadness of the PSD.     

Preparation of poly(N‐ethyl methacrylamide) particles via an emulsion/precipitation process: The role of the crosslinker

Monodisperse, thermosensitive poly(N‐ethyl methacrylamide) microgel particles were prepared by the batch precipitation/emulsion polymerization of water‐soluble N‐ethyl methacrylamide and the hydrophobic crosslinker ethylene glycol dimethacrylate initiated by potassium persulfate. Particular attention was paid to the effect of the crosslinker agent on the polymerization process (kinetics, conversion, and water‐soluble oligomer content). Particles were characterized in terms of their size distribution and swelling capacity. A polymerization mechanism for the water‐soluble monomer and non‐water‐soluble crosslinker is proposed and discussed on the basis of a combination of both emulsion and precipitation polymerization processes. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 1808–1817, 2002     

KINETICS OF SUSPENDED EMULSION POLYMERIZATION OF METHYL METHACRYLATE*

 The kinetics of suspended emulsion polymerization of methyl methacrylate (MMA), in which water acted as the dispersed phase and the mixture of MMA and cyclohexane as the continuous phase, was investigated. It showed that the initial polymerization rate (R_p0) and steady-state polymerization rate (R_p) were proportional to the mass ratio between water and oil phase, and increased as the polymerization temperature, the potassium persulphate concentration ([I]) and the Tween20 emulsifier concentration ([S]) increased. The relationships between the polymerization rate and [I] and [S] were obtained as follows: R_p0∝[I]^0.71[S]^0.23.The above exponents were close to those obtained from normal MMA emulsion polymerization. It also showed that the average molecular weight of the resulting poly(methylmethacrylate) decreased as the polymerization temperature,[I]and [S] increased. Thus, MMA suspended emulsion polymerization could be considered as a combination of many miniature emulsion polymerizations proceeding in water drops and obeyed the classical kinetics of MMA emulsion polymerization.     

Molecular weight development in constant-rate styrene emulsion polymerization

Continuously uniform latices were applied in an experimental study of molecular weight development in constant-rate styrene emulsion polymerization. The formulation around which this study centered exhibited Smith-Ewart, case II kinetics from zero to about 60% conversion with a constant conversion rate of 13 ± 2%/hr and a final particle diameter of 2300 Å. By utilizing an inhibitor perturbation technique, we directly confirmed that free radicals are generated from K₂S₂O₈ by a first-order process with 100% efficiency. We further confirmed that, in contrast to current theories for constant rate polymerization, both the instantaneous values of M?_n and M?_v may increase 6- to 9-fold. Little or no chain branching is evidenced. We interpret these findings to mean that radicals are not utilized with 100% efficiency in emulsion polymerization.     

Kinetics of polymerization of styrene-in-water microemulsions

The kinetics of polymerization of styrene-in-water microemulsions was investigated using dilatometry. From plots of percentage conversion versus time, the rate of polymerization, R _p, was determined. From log-log plots of R _p versus styrene and initiator [2,2′-azobis(isobutyronitrile), AIBN] concentrations the following relationship was established: R _p∝ [styrene]^1.2 [AIBN]^0.46. These exponents are similar to those predicted by the theory of emulsion polymerization. The results also showed a rapid conversion in the initial period (interval 1) followed by a slower rate at longer times (interval 2). It was suggested that in interval 1, the main process in nucleation of the microemulsion droplets, whereas in interval 2 propagation is the more dominant factor. The rapid polymerization of microemulsions is consistent with their structure, whereby very small droplets with flexible interfaces are produced. Received: 2 March 1999 Accepted in revised form: 10 May 1999     

Characterization and study of microwave activation effects on the polystyrene tacticity

¹³C Nuclear magnetic resonance proved to be an advantageous tool to determine the stereoregularity of polystyrene polymers. The latter was achieved through the analysis of the signal of the quaternary carbon and that of the carbon-p in the aromatic ring too. Styrene was polymerized through microwaves and conventional heating activation using two different polymerization techniques: emulsion and bulk. Microwave activation was performed in a mono-modal type device under the following experimental conditions: various initiator concentrations, an average irradiation power of 50?W, temperature of 70°C, and using a batch reactor for emulsion and bulk experiments. The results obtained in these experiments were compared with those obtained by conventional heating activation polymerization under the same initiator concentration and temperature conditions. Microwave-activated reactions resulted in shorter reaction times and higher yields. The tacticity of the polymer samples was not significantly altered, which lead to the conclusion that, in this case, the stereoregularity of polystyrene was not influenced by microwave irradiation.     

Effects of surface charge density on emulsion kinetics and secondary particle formation in emulsifier-free seeded emulsion polymerization of methyl methacrylate

 Experiments were carried out to investigate the effects of surface charge density on emulsion kinetics and secondary particle formation in emulsifier-free seeded emulsion polymerization. Three monodisperse seed latices with different surface charge densities were prepared from styrene/NaSS comonomers using the two-stage shot-growth process. After purification of the seed latices, they were used in seeded emulsion polymerization of methyl methacrylate. The initial rate of poly-merization and the average number of radicals per particle for the high-charged seed latex system were lower than that of the low-charged case. The low rate of polymerization resulted from the low rate of radical adsorption in the beginning of the reaction due to the electrical repulsion between seeds and oligomeric radicals. In this case, because of the secondary particles, particle size distribution became bimodal. The low rate of radical adsorption and the formation of secondary particles reduced the average number of radicals per particle. The rate of polymerization (R _p) increased, but the rate of polymerization per particle (R _p/N _p) decreased. Received: 9 December 1996 Accepted: 7 March 1997     

RAFT‐mediated emulsion polymerization of styrene using brush copolymer as surfactant macro‐RAFT agent: Effect of the brush copolymer sequence and chemical composition

The nonionic amphiphilic brush polymers such as poly[poly(ethylene oxide) methyl ether vinylphenyl‐co‐styrene] trithiocarbonate [P(mPEGV‐co‐St)‐TTC] and poly[poly(ethylene oxide) methyl ether vinylphenyl‐b‐styrene‐b‐poly(ethylene oxide) methyl ether vinylphenyl] trithiocarbonate [P(mPEGV‐b‐St‐b‐mPEGV)‐TTC] with different monomer sequence and chemical composition are synthesized and their application as macro‐RAFT agent in the emulsion RAFT polymerization of styrene is explored. It is found that the monomer sequence in the brush polymers exerts great influence on the emulsion RAFT polymerization kinetics, and the fast polymerization with short induction period in the presence of P(mPEGV‐co‐St)‐TTC is demonstrated. Besides, the chemical composition in the brush polymer macro‐RAFT agent effect on the emulsion RAFT polymerization is investigated, and the macro‐RAFT agent with high percent of the hydrophobic PS segment leads to fast and well controlled polymerization. The growth of triblock copolymer colloids in the emulsion polymerization is checked, and it reveals that the colloidal morphology is ascribed to the hydrophobic PS block extension, and the P(mPEGV‐co‐St) block almost have no influence just on the size of the colloids. This may be the first example to study the monomer sequence and the chemical composition in the macro‐RAFT agent on emulsion RAFT polymerization, and will be useful to reveal the block copolymer particle growth. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2013     

Estimation of morphology of composite polymer emulsion particles by the soap titration method

The occupied area (A_m) of a sodium dodecyl benzene sulfonate molecule adsorbed on particles was measured by the soap titration method. The A_m values are 214, 133, and 53 Ų for poly(methyl acrylate) (I), poly(methyl methacrylate) (II), and polystyrene (III), respectively. For methyl metharylate-styrene copolymer emulsions the additivity was established between the A_m value and copolymer composition. Composite emulsion particles consisting of I/II, I/III, and II/III were prepared by seeded emulsion polymerization. For these emulsions the relationship between polymer composition at the surface layer calculated from the A_m value and that in a particle calculated from the polymerization process was investigated. This relationship is remarkably affected by the order of polymerization, the hydrophilicity of polymer, the flexibility of the seed polymer, and the monomer addition method. The models of the morphology of these composite particles explain the results successfully.     

Kinetics and mechanism of emulsifier-free emulsion polymerization. II. Styrene/water soluble comonomer (sodium methallyl sulfonate) system

The emulsifier-free emulsion polymerizations of styrene in the presence of about 1 wt% (related to styrene) of the water soluble comonomer, sodium methallyl sulfonate (NaMS), which has short hydrophobic group and strong hydrophilic ionic group, and of the initiator, potassium persulfate, are carried out. Under constant ionic strength, the number density of polymer particles (N_p) is found to depend on 0.5-power of the initiator concentration and shows a minimum in the comonomer concentration plot. Under constant concentration of monomer, comonomer and initiator, N_p is found to depend on ?1.1-power of the ionic strength. In the earlier period, the presence of styrene oligomer having MW about 1000 and water soluble poly(NaMS) or copolymer with high NaMS content suggests a micellar nucleation mechanism, by which the styrene oligomer behaves as emulsifier and the poly(NaMS) can either stabilize or destabilize the existing particles, depending on its concentration in the aqueous phase. The particle size is rather uniform having an uniformity very close to 1 (ca. 1.001) throughout the entire process. It is much larger than that of the conventional emulsion polymerization or emulsifier-free emulsion polymerization with the other comonomers by about 3 to 4 times in diameter or 27 to 64 times in volume, leading to that the average radical number in the particle could be much greater than 0.5. The (conversion)^2/3 versus time plot is found to be linear from 6 to 50% conversion. During this period, for the conversion from 10 to 40% the polymerization rate increases twice but the particle volume increases four-fold. In addition, MWD shows bimodal (excluding the styrene oligomer peak in the earlier period) during the growth period. But the lower MW peak shifts to higher MW and become larger, while the higher MW peak decreases, and finally the MWD becomes single mode after 58.6% conversion. These results suggest a “gradient polymerization” or “transition stage to core-shell structure” in the earlier stage of particle growth and a “shell part polymerization” in the later stage.     

Synthesis of polystyrene-block-polyoxyethylene for use as a stabilizer in the emulsion polymerization of styrene

Five well-defined polystyrene-block-polyoxyethylene copolymers were synthesized by anionic polymerization for use as stabilizers in the emulsion polymerization of styrene. The size of the blocks and their relative weight ratios to each other were the main variables. The molecular weights of the blocks varied from M?_n = 1000–7000 for polystyrene, and M?_w = 3000–9000 for polyoxyethylene. The results of the styrene emulsion polymerization with these block copolymers as stabilizers indicate that for efficient anchoring the block length need not be more than 10 monomer units, possibly even less, and that the polyoxyethylene block M?_w = 3000 is just as capable of stabilizing the polystyrene particle as the higher molecular weight blocks. A very important factor was found to be the weight ratio of the two blocks: block copolymers with a polyoxyethylene content between 75 and 90 wt % were effective stabilizers for the emulsion polymerization of styrene © 1992 John Wiley & Sons, Inc.