Emulsion polymerization reaction kinetics

Other parts of this book contain detailed discussions of emulsion polymerization mechanisms, kinetics, and reaction en neering. Thus, the intent of this chapter is to introduce the reader to some of the basic concepts of continuous reactor systons. A rather simple steady-state reactor model will be presented for a sin e CSTR system. This model will be compared with a batch reactor model for the same reaction mechanism and the model differences highlighted. 

The colloidal nature of the reaction media has a significant influence on the course of an emulsion polymerization reaction. A number of distinct phases exist during different intervals of a batch reaction. Chemical and physical phenomena within these phases and at the interfaces can be important in determining reaction kinetics and the properties of the latex product. 

Summary. All of the phases and the physical and chemical mechanisms discussed in this section are important during the course of an emulsion polymerization reaction. They influence the reaction kinetics and the properties of the latex produced. Not all of the phenomena that can occur are understood in a quantitative manner. Nevertheless, considerable advances have been made in the fundamental understanding and the commercial exploitation of emulsion polymerization processes. The remainder of this chapter will focus on reactor types and reaction kinetics. 

The kinetics of emulsion polymerization reactions are complex because of the numerous chemical and physical phenomena that can occur in the multicomponent, multiphase mixture. A large amount of literature exists on kinetics problems. The general references listed at the end of this chapter contain many important papers. The review paper by Ugelstad and Hansen (11) is a comprehensive treatment of batch kinetics. The purpose of the remainder of this chapter is to present the general kinetics problems and some of the published results. The reader should use the references cited earlier for a more detailed study. 

In a heterogeneous reaction system (as in emulsion polymerization), the kinetics change considerably. Basically, such a system uses a soap (i.e., sodium or potassium salts of sulfates or organic acids) that allows the creation of micelles (agglomerations of anions). These micelles serve as accumulations of monomer and ultimately as polymerization sites. It can be shown that... 

Fig. 1.23 Full scheme of kinetics process in a typical emulsion polymerization reaction (Reprinted from Thickett and Gilbert [274]. Copyright 2009, with permission from Elsevier)...

Emulsion polymerization reactions have also been carried out in tubular reactor systems. Single-pass (straight through) tubular reactors have been used for a number of kinetic studies in academic institutions (3,4). To the best of my knowledge, however, such tubular reactor systems have not been commercialized. 

Several reports have been published on the in-line monitoring of vinyl acetate emulsion polymerization reactions in semibatch mode [22]. With appropriate models, this approach can provide good feedback about the polymerization reaction kinetics. Heat flow calorimetry (Hfc) is frequently used to... 

Surfactants provide temporary emulsion droplet stabilization of monomer droplets in tire two-phase reaction mixture obtained in emulsion polymerization. A cartoon of tliis process is given in figure C2.3.11. There we see tliat a reservoir of polymerizable monomer exists in a relatively large droplet (of tire order of tire size of tire wavelengtli of light or larger) kinetically stabilized by surfactant. 

Kinetics and Mechanisms. Early researchers misunderstood the fast reaction rates and high molecular weights of emulsion polymerization (11). In 1945 the first recognized quaHtative theory of emulsion polymerization was presented (12). This mechanism for classic emulsion preparation was quantified (13) and the polymerization separated into three stages. 

Copolymers with butadiene, ie, those containing at least 60 wt % butadiene, are an important family of mbbers. In addition to synthetic mbber, these compositions have extensive uses as paper coatings, water-based paints, and carpet backing. Because of unfavorable reaction kinetics in a mass system, these copolymers are made in an emulsion polymerization system, which favors chain propagation but not termination (199). The result is economically acceptable rates with desirable chain lengths. Usually such processes are mn batchwise in order to achieve satisfactory particle size distribution. 

The concentration of monomers in the aqueous phase is usually very low. This means that there is a greater chance that the initiator-derived radicals (I ) will undergo side reactions. Processes such as radical-radical reaction involving the initiator-derived and oligomeric species, primary radical termination, and transfer to initiator can be much more significant than in bulk, solution, or suspension polymerization and initiator efficiencies in emulsion polymerization are often very low. Initiation kinetics in emulsion polymerization are defined in terms of the entry coefficient (p) - a pseudo-first order rate coefficient for particle entry. 

Continuous emulsion polymerization systems are studied to elucidate reaction mechanisms and to generate the knowledge necessary for the development of commercial continuous processes. Problems encountered with the development of continuous reactor systems and some of the ways of dealing with these problems will be discussed in this paper. Those interested in more detailed information on chemical mechanisms and theoretical models should consult the review papers by Ugelstad and Hansen (1), (kinetics and mechanisms) and by Poehlein and Dougherty (2, (continuous emulsion polymerization). 

In an emulsion polymerization, the reaction mixture is initially heterogeneous due to the poor solubility of the monomer in the continuous phase. In order for a reaction to take advantage of the desirable Smith-Ewart kinetics [96], the monomer and initiator must be segregated with the initiator preferentially dissolved in the continuous phase and not the monomer phase. Because of the kinetics of an emulsion polymerization, high molecular weight polymer can be produced at high rates. The polymer which results from an emulsion polymerization exists as spherical particles typically smaller than one pm in diameter. However, due to the high solubility of most vinyl monomers in C02, emulsion polymerization in C02 probably will not be a very useful process for commercially important monomers. 

Dispersion polymerization involves an initially homogeneous system of monomer, organic solvent, initiator, and particle stabilizer (usually uncharged polymers such as poly(A-vinyl-pyrrolidinone) and hydroxypropyl cellulose). The system becomes heterogeneous on polymerization because the polymer is insoluble in the solvent. Polymer particles are stabilized by adsorption of the particle stabilizer [Yasuda et al., 2001], Polymerization proceeds in the polymer particles as they absorb monomer from the continuous phase. Dispersion polymerization usually yields polymer particles with sizes in between those obtained by emulsion and suspension polymerizations—about 1-10 pm in diameter. For the larger particle sizes, the reaction characteristics are the same as in suspension polymerization. For the smallest particle sizes, suspension polymerization may exhibit the compartmentalized kinetics of emulsion polymerization. 

Although the above derivations involve certain simplifications, they nevertheless represent correctly the kinetics of many addition polymerization reactions. However, the behavior is different when the polymerization is conducted under heterogeneous conditions, e.g., in suspension or in emulsion (see literature cited in Sect. 2.2.4). 

An interesting variation on the use of azo groups-containing polymers is the use of polyacrylamide prepolymers as both initiator and emulsifying agent for the emulsion polymerization of vinyl acetate. The observed reaction kinetics were typical (see Fig. 4.7) for an emulsion polymerization and, in particular, the slope (a = 1) of the plot of lg Rp vs lg CPrep confirms the double function of these prepolymers very clearly. 

In the foregoing examples the synthesis of block copolymers was based on the solubility differences between two monomers, of which one is water soluble while the other is emulsified. Another polymerization technique is based on the kinetics of the emulsion polymerization. When a water emulsion of a monomer, such as styrene, is irradiated during a short time, the reaction, continues at a nearly steady rate until practically all the monomer is used up. If a second monomer is then added, it will polymerize, being initiated by the radicals occluded in the polymer particles. Although in this case also the yields of block copolymers are low, nevertheless the physical properties of the final product are markedly different from those of statistical copolymers (4, 5, 151, 176). 

Several methodologies for preparation of monodisperse polymer particles are known [1]. Among them, dispersion polymerization in polar media has often been used because of the versatility and simplicity of the process. So far, the dispersion polymerizations and copolymerizations of hydrophobic classical monomers such as styrene (St), methyl methacrylate (MMA), etc., have been extensively investigated, in which the kinetic, molecular weight and colloidal parameters could be controlled by reaction conditions [6]. The preparation of monodisperse polymer particles in the range 1-20 pm is particularly challenging because it is just between the limits of particle size of conventional emulsion polymerization (100-700 nm) and suspension polymerization (20-1000 pm). 

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