Ethylene free-radical polymerization

Even though vinyl chloride was discovered in 1835, polyvinyl chloride was not produced until 1912. It is now one of our most common polymers production in 1984 was over 6 billion pounds. The monomer is made by the pyrolysis of 1,2-dichloroethane, formed by chlorination of ethylene. Free radical polymerization follows Markovnikov s rule to give the head-to-tail polymer with high specificity ... 

The monomer ethylbenzene is made from petroleum-derived benzene and ethylene. Free radical polymerization is usually carried out in the gas phase with an iron oxide or other metal oxide catalyst yielding PS resin ... 

Dimerization in concentrated sulfuric acid occurs mainly with those alkenes that form tertiary carbocations In some cases reaction conditions can be developed that favor the formation of higher molecular weight polymers Because these reactions proceed by way of carbocation intermediates the process is referred to as cationic polymerization We made special mention m Section 5 1 of the enormous volume of ethylene and propene production in the petrochemical industry The accompanying box summarizes the principal uses of these alkenes Most of the ethylene is converted to polyethylene, a high molecular weight polymer of ethylene Polyethylene cannot be prepared by cationic polymerization but is the simplest example of a polymer that is produced on a large scale by free radical polymerization... 

In the free radical polymerization of ethylene ethylene is heated at high pressure in the presence of oxygen or a peroxide... 

FIGURE 6 17 Mechanism of peroxide initiated free radical polymerization of ethylene... 

The mechanism of free radical polymerization of ethylene is outlined m Figure 6 17 Dissociation of a peroxide initiates the process m step 1 The resulting per oxy radical adds to the carbon-carbon double bond m step 2 giving a new radical which then adds to a second molecule of ethylene m step 3 The carbon-carbon bond forming process m step 3 can be repeated thousands of times to give long carbon chains... 

Tetrafluoroethylene of purity suitable for granular or dispersion polymerizations is acceptable for copolymerization with ethylene. Polymerization-grade ethylene is suitable for copolymerization with tetrafluoroethylene. Modifying termonomers, eg, perfluorobutylethylene and perfluoropropylene, are incorporated by free-radical polymerization. 

The nmr spectmm of PVAc iu carbon tetrachloride solution at 110°C shows absorptions at 4.86 5 (pentad) of the methine proton 1.78 5 (triad) of the methylene group and 1.98 5, 1.96 5, and 1.94 5, which are the resonances of the acetate methyls iu isotactic, heterotactic, and syndiotactic triads, respectively. Poly(vinyl acetate) produced by normal free-radical polymerization is completely atactic and noncrystalline. The nmr spectra of ethylene vinyl acetate copolymers have also been obtained (33). The ir spectra of the copolymers of vinyl acetate differ from that of the homopolymer depending on the identity of the comonomers and their proportion. 

Reaction conditions for the free radical polymerization of ethylene are 100-200°C and 100-135 atmospheres. Ethylene conversion is kept to a low level (10-25%) to control the heat and the viscosity. However, overall conversion with recycle is over 95%. 

Chemical methods for structure determination in diene pol3 mers have in large measure been superseded by infrared absorption techniques. By comparing the infrared absorption spectra of polybutadiene and of the olefins chosen as models whose ethylenic structures correspond to the respective structural units, it has been possible to show that the bands occurring at 910.5, 966.5, and 724 cm. are characteristic of the 1,2, the mns-1,4, and the m-1,4 units, respectively. Moreover, the proportion of each unit may be determined within 1 or 2 percent from measurements of the absorption intensity in each band. The extinction coefficients characteristic of each structure must, of course, be known these may be assigned from intensity measurements on model compounds. Since the proportions of the various units depend on the rates of competitive reactions, their percentages may be expected to vary with the polymerization temperature. The 1,2 unit occurs to the extent of 18 to 22 percent of the total, almost independent of the temperature, in free-radical-polymerized (emulsion or mass) poly butadiene. The ratio of trans-1,4 to cfs-1,4, however,... 

Figure 2.4 Examples of monomers that can undergo free radical polymerization a) ethylene, b) vinyl chloride and c) styrene...

We make polyethylene resins using two basic types of chain growth reaction free radical polymerization and coordination catalysis. We use free radical polymerization to make low density polyethylene, ethylene-vinyl ester copolymers, and the ethylene-acrylic acid copolymer precursors for ethylene ionomers. We employ coordination catalysts to make high density polyethylene, linear low density polyethylene, and very low density polyethylene. 

It was discovered by Ziegler in Germany and Natta in Italy in the 1950s that metal alkyls were very efficient catalysts to promote ethylene polymerization at low pressures and low temperatures, where free-radical polymerization is very slow. They further found that the polymer they produced had fewer side chairrs because there were fewer growth mistakes caused by chain transfer and radical recombination. Therefore, this polymer was more crystalline and had a higher density than polymer prepared by free-radical processes. Thus were discovered linear and high-density polymers. 

Because the size of the emulsion droplets dictates the diameter of the resulting capsules, it is possible to use miniemulsions to make nanocapsules. To cite a recent example, Carlos Co and his group developed relatively monodisperse 200-nm capsules by interfacial free-radical polymerization (Scott et al. 2005). Dibutyl maleate in hexadecane was dispersed in a miniemulsion of poly(ethylene glycol)-1000 (PEG-1000) divinyl ether in an aqueous phase. They generated the miniemulsion by sonication and used an interfacially active initiator, 2,2 -azobis(A-octyl-2-methyl-propionamidine) dihydrochloride, to initiate the reaction, coupled with UV irradiation. 

Taylor in 1925 demonstrated that hydrogen atoms generated by the mercury sensitized photodecomposition of hydrogen gas add to ethylene to form ethyl radicals, which were proposed to react with H2 to give the observed ethane and another hydrogen atom. Evidence that polymerization could occur by free radical reactions was found by Taylor and Jones in 1930, by the observation that ethyl radicals formed by the gas phase pyrolysis of diethylmercury or tetraethyllead initiated the polymerization of ethylene, and this process was extended to the solution phase by Cramer. The mechanism of equation (37) (with participation by a third body) was presented for the reaction, - which is in accord with current views, and the mechanism of equation (38) was shown for disproportionation. Staudinger in 1932 wrote a mechanism for free radical polymerization of styrene,but just as did Rice and Rice (equation 32), showed the radical attack on the most substituted carbon (anti-Markovnikov attack). The correct orientation was shown by Flory in 1937. In 1935, O.K. Rice and Sickman reported that ethylene polymerization was also induced by methyl radicals generated from thermolysis of azomethane. 

As mentioned in Section 9.3, Jackson (141) has obtained estimates of the chain-transfer coefficient of the growing radical with polymer in the free-radical polymerization of ethylene, C,p, by choosing the value so as to fit the MWD. As the polymerization conditions for the polymers mentioned in Table 10.1 are not disclosed, it is necessary to choose typical conditions 220° C and 2000 atm will be selected. Under these conditions Ctp, the ratio of the rate constant for attack on polymer (per monomer unit) to that for propagation, in a homogeneous phase, was found to be about 4.0 x 10 3. This is in good agreement with the known transfer coefficients for the lower alkanes (160), when allowance is made for the differences in pressure and temperature (100). The relation between Ctp and k is ... 

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