Batch monomer distribution

Most of the above results are valid or the "corrected batch process" where styrene is added to the reactor in order to keep the AN/S ratio constant. Monomer distribution in the various phases, shown in figure 11, for an experiment with initial charge ... 

Before polyacrylamides are sold, the amount of residual acrylamide is determined. In one method, the monomer is extracted from the polymer and the acrylamide content is determined by hplc (153). A second method is based on analysis by cationic exchange chromatography (154). For dry products the particle si2e distribution can be quickly determined by use of a shaker and a series of test sieves. Batches with small particles can present a dust ha2ard. The percentage of insoluble material is determined in both dry and emulsion products. 

In the most common production method, the semibatch process, about 10% of the preemulsified monomer is added to the deionised water in the reactor. A shot of initiator is added to the reactor to create the seed. Some manufacturers use master batches of seed to avoid variation in this step. Having set the number of particles in the pot, the remaining monomer and, in some cases, additional initiator are added over time. Typical feed times ate 1—4 h. Lengthening the feeds tempers heat generation and provides for uniform comonomer sequence distributions (67). Sometimes skewed monomer feeds are used to offset differences in monomer reactivity ratios. In some cases a second monomer charge is made to produce core—shell latices. At the end of the process pH adjustments are often made. The product is then pumped to a prefilter tank, filtered, and pumped to a post-filter tank where additional processing can occur. When the feed rate of monomer during semibatch production is very low, the reactor is said to be monomer starved. Under these... 

During copolymerization, one monomer may add to the copolymer more rapidly than the other. Except for the unusual case of equal reactivity ratios, batch reactions carried to completion yield polymers of broad composition distribution. More often than not, this is an undesirable result. 

The present section analyzes the above concepts in detail. There are many different mathematical methods for analyzing molecular weight distributions. The method of moments is particularly easy when applied to a living pol5mer polymerization. Equation (13.30) shows the propagation reaction, each step of which consumes one monomer molecule. Assume equal reactivity. Then for a batch polymerization. 

In a batch reactor, the relative monomer concentrations will change with time because the two monomers react at different rates. For polymerizations with a short chain life, the change in monomer concentration results in a copolymer composition distribution where polymer molecules formed early in the batch will have a different composition from molecules formed late in the batch. For living polymers, the drift in monomer composition causes a corresponding change down the growing chain. This phenomenon can be used advantageously to produce tapered block copolymers. 

Example 13.7 A 50/50 (molar) mixture of st5Tene and acrylonitrile is batch polymerized by free-radical kinetics until 80% molar conversion of the monomers is achieved. Determine the copolymer composition distribution. 

Addition of a core compound even in a batch wise polymerization makes the distribution narrower. This problem can simply be handled by TBP. If one starts with a core and the monomer is gradually added, the distribution can be narrowed even more [51, 83-87]. This follows from kinetic simulations. However, the monomer addition method has certain limits. It is effective for low molecular weights, so that B groups are almost absent in all initial larger molecules. Unless the monomer addition is infinitesimally slow, which is impractical, condensates by reactions between the monomers are formed containing B... 

The loci and concentration of these functional groups often determine the latex performance in a given application. Therefore, it is important to know the distribution of functional groups between the serum, particle surface, and particle interior as a function of the type and concentration of the functional monomer and the technique of polymerization. Thus characterization methods developed to determine the loci of these functional groups are useful in research to develop new latexes and modifications of older latexes, in development to ensure that the scale-up does not result in a change in the loci of the functional groups, and in production to ensure batch-to-batch uniformity of the product. 

Vinyl acetate-butyl acrylate copolymers (0-100% butyl acrylate) were prepared by both batch and starved semi-continuous polymerization using sodium lauryl sulfate emulsifier, potassium persulfate initiator, and sodium bicarbonate buffer. This copolymer system was selected, not only because of its industrial importance, but also because of its copolymerization reactivity ratios, which predict a critical dependence of copolymer compositional distribution on the technique of polymerization. The butyl acrylate is so much more reactive than the vinyl acetate that batch polymerization of any monomer ratio would be expected to give a butyl acrylate-rich copolymer until the butyl acrylate is exhausted and polyvinyl acetate thereafter. 

The results showed that all batch polymerizations gave a two-peaked copolymer compositional distribution, a butyl acrylate-rich fraction, which varied according to the monomer ratio, and polyvinyl acetate. All starved semi-continuous polymerizations gave a single-peaked copolymer compositional distribution which corresponded to the monomer ratio. The latex particle sizes and type and concentration of surface groups were correlated with the conditions of polymerization. The stability of the latex to added electrolyte showed that particles were stabilized by both electrostatic and steric stabilization with the steric stabilization groups provided by surface hydrolysis of vinyl acetate units in the polymer chain. The extent of this surface hydrolysis was greater for the starved semi-continuous sample than for the batch sample. 

Although MAA monomer possesses a larger reactivity ratio than MMA monomer, more MAA was found to exist in the outer side of the particle in the batch latex, as shown in Figures 5 and 6. This behavior could be explained if one can accept the fact that the MAA-rich polymers, which are formed early on during the polymerization, can migrate to the surface of the particle due to their higher hydrophilicity and plasticization of the polymer with the monomer. In the semi-continuous process, it could be expected that copolymer with the same composition as the comonomer feed is formed, and the particle contains a uniform distribution of carboxyl groups. 

For example, the formation of living polymers allows the preparation of block polymers by sequential addition of monomers. It also permits the introduction of functional groups on the ends of each chain. From kinetic considerations of live polymer systems, it follows that, in a batch reaction, a fast initiation step relative to the propagation step will result in a very narrow molecular-weight distribution. It also follows that the molecular weight will be directly proportional to the mole ratio of initiator to monomer. 

Yoshida and coworkers also developed a microreaction system for cation pool-initiated polymerization [62]. Significant control of the molecular weight distribution (Mw/Mn) was achieved when N-acyliminium ion-initiated polymerization of butyl vinyl ether was carried out in a microflow system (an IMM micromixer and a microtube reactor). Initiator and monomer were mixed using a micromixer, which was connected to a microtube reactor for the propagation step. The polymerization reaction was quenched by an amine in a second micromixer. The tighter molecular weight distribution (Mw/M = 1.14) in the microflow system compared with that of the batch system (Mw/M > 2) was attributed to the very rapid mixing and precise control of the polymerization temperature in the microflow system. 

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