Modeling of pore formation in phase inversion processes: analysis of pore formation mechanism

The phase inversion process is the most important preparation process of porous polymer membranes. Recently, a numerical model based on first principles to predict pore structures has been proposed (Hopp-Hirschler and Nieken in J Membr Sci 564:820–831, 2018). This model enables a detailed investigation of the mechanism of pore formation in porous polymer membranes. This follow-up presents investigations of the mechanism of nucleation of pores during the phase inversion process in 1D. Pores originate due to accumulation of over-saturated mixtures inside a diffuse interface between homogeneous and demixed polymer solutions behind the precipitation front. This is caused by an expansion of the width of the diffuse interface and time-dependent concentration profiles which finally lead to a change of sign of total diffusive mass flux inside of the diffuse interface. As a result, oscillating compositions behind the precipitation front lead to formation of pores. It is concluded that large surface tension leads to initially small pore sizes. In the second part, a detailed discussion of directional diffusion behind the precipitation front is presented in 2D, which is responsible for different pore structures, e.g., finger or sponge pores. Depending on the dominant direction of diffusion finger pores, lamella structures or sponge pores are formed. This picture can straightforwardly be extended to 3D structures.

     

Thin Organic-Inorganic Anti-Fouling Hybrid-Films for Microreactor Components

Deposit formation and fouling in reactors for polymer production and processing especially in microreactors is a well-known phenomenon. Despite the flow and pressure loss optimized static mixers, fouling occurs on the surfaces of the mixer elements. To improve the performance of such parts even further, stainless steel substrates are coated with ultra-thin films which have low surface energy, good adhesion, and high durability. Perfluorinated organosilane (FOTS) films deposited via chemical vapor deposition (CVD) are compared with FOTS containing zirconium oxide sol-gel films regarding the prevention of deposit formation and fouling during polymerization processes in microreactors. Both film structures led to anti-adhesive properties of microreactor component surfaces during aqueous poly(vinylpyrrolidone) (PVP) synthesis. To determine the morphology and surface chemistry of the coatings, different characterization methods such as X-ray photoelectron spectroscopy (XPS) and Fourier transform infrared (FTIR) spectroscopy as well as microscopic methods such as field-emission scanning electron microscopy (FE-SEM) and atomic force microscopy (AFM) are applied. The surface free energy and wetting properties are analyzed by means of contact angle measurements. The application of thin film-coated mixing elements in a microreactor demonstrates a significant lowering in pressure increase caused by a reduced deposit formation.     

Measurement of Capillary Pressure–Saturation Relationships Under Defined Compression Levels for Gas Diffusion Media of PEM Fuel Cells

Measurements of capillary pressure–saturation relationships under defined levels of compression for gas diffusion layers (GDL) of polymer electrolyte membrane fuel cells as thin, mixed-wettable porous media have been carried out in a newly constructed device. This article lines out the construction principle of the cell and the preconditioning procedure of the sample to measure the capillary pressure–saturation relationships under well-defined conditions and loads of compression. Three commercial GDLs (Freudenberg H2315T10A, H2315T10AC1, and SGL Carbon BA24) have been examined and a compression-depending hysteresis of the capillary pressure–saturation relationship has been measured and identified.     

Side Reactions in Aqueous Phase Polymerization of N‐Vinyl‐Pyrrolidone as Possible Source for Fouling

An improved kinetic model for the radical polymerization of N‐vinyl‐pyrrolidone (NVP) in aqueous medium is developed. Quantum chemical simulations reveal that the transfer to polymer is of minor importance whereas the transfer to monomer by hydrogen abstraction in 3‐position of the pyrrolidone ring leads to a radical with a double bond which initiates a new chain bearing a terminal double bond (TDB). The resulting dead chains with one, two, or more TDB are the main source for a strong increase of molar mass in batch reactors at high conversion due to long chain branching and crosslinking. This can be a source for gel formation and fouling in continuous reactors.     

Styrene synthesis over iron oxide catalysts: from single crystal model system to real catalysts

Surface science methods originating from analysis of noble metal catalysts are increasingly applied to metal oxides. These methods provide direct access to fundamental structural properties and phase equilibria governing the catalytic properties of metal oxide surfaces. However, no systematic way existed so far for transferring this knowledge to technical catalysts. The aim of this paper is to combine surface science with chemical engineering methods to bridge this gap. Styrene synthesis over pure and K-doped iron oxides is used as an example to develop and to explain the methodology. Single crystal films (SCF), grown epitaxially on a Pt-carrier are considered as ideal model surfaces. Comprehensive UHV analyses yield the structural properties of SCF as well as their interaction with relevant components of the reaction mixture. Their results are combined with conversion experiments to derive a mechanistic catalyst model along with quantitative information on the reaction rates. The activity of SCF as well as their phase transitions under reactive conditions can be described with a continuum model depending on the macroscopic properties of the system. This model forms the crucial link towards technical catalysts. It is shown that the behaviour of a powder catalyst can be described as a superposition of the above kinetic model and an appropriate porous model. In this paper we review the developed methodology and conclude with the evaluation of the concept.     

Modeling Strategies for the Propagation of Terminal Double Bonds During the Polymerization of N‐Vinylpyrrolidone and Experimental Validation

Based on a recently suggested reaction mechanism, which involves the production and propagation of terminal double bonds (TDBs), kinetic models for the polymerization of N‐vinylpyrrolidone in aqueous solution are developed. Two modeling strategies, the classes and the pseudodistribution approach, are applied to handle the multidimensional property distributions that result from this reaction mechanism and to get detailed structural property information, e.g., on the chain length distribution and the distribution of TDBs. The structural property information is then used to develop reduced models with significantly lower computational effort, which can be used for process design, on‐line applications or coupled to computational fluid dynamic simulations. To validate the derivations, the models are first compared against each other and finally to experimental results from a continuous stirred tank reactor. The evolution of monomer conversion and molecular weight average data as well as molecular weight distributions can be represented very well by the models that are derived in this article. These results support the correctness of the reaction mechanism predicted by quantum mechanical simulations.     

Modeling of Diffusive Transport of Polymers Moments Using Limiting Cases of the Maxwell–Stefan Model

A polymer distribution is usually represented by its moments. Thus, to calculate transport in a polymer system, a formulation for the transport of moments of the polymer is needed. This is only possible if the moments close or if there is a suitable closing condition. To archive this, two simplifications of the Stefan–Maxwell diffusion are derived, which convert the transport equation of polymeric species to a closed set of transport equations for the polymer moments. The first approach corresponds to an infinitely diluted polymer system, whereas the second one describes a highly concentrated polymer system. Both formulations are compared with the full Stefan-Maxwell model of a ternary mixture of a solvent and two polymer species of different chain length.