Gas and polymerization

Dining chlorination of styrene in carbon tetrachloride at 50°C, a violent reaction occurred when some 10% of the chlorine gas had been fed in. Laboratory examination showed that the eruption was caused by a rapid decomposition reaction catalysed by ferric chloride [1], Various aromatic monomers decomposed in this way when treated with gaseous chlorine or hydrogen chloride (either neat, or in a solvent) in the presence of steel or iron(III) chloride. Exotherms of 90°C (in 50% solvent) to 200°C (no solvent) were observed, and much gas and polymeric residue was forcibly ejected. 

There are two kinds of modified batch experiments that allow us to keep F constant The first possibility arises in cases where one of the monomers is liquid and the other is a gas, and polymerization takes place in pure liquid comonomer under constant pressure of the gaseous comonomer. The second possibility is to pass the mixture of both monomers (gases or liquids) into the reactor at a rate equal to the rate of copolymerization (25). Such experiments have setting periods, which can be avoided by the preparation of two monomer mixtures — one to fill the reactor (with the monomer ratio F) and the second for permanent feeding (with the monomer ratio /, i.e. with a ratio corresponding to the composition of the forming copolymer) (26). The other possibility of copolymer synthesis in stationary conditions is continuous copolymerization. 

AH technologies employed for catalytic polymerization processes in general are widely used for the manufacture of HDPE. The two most often used technologies are slurry polymerization and gas-phase polymerization. Catalysts are usuaHy fine-tuned for a particular process. 

Gas-phase polymerization of propylene was pioneered by BASF, who developed the Novolen process which uses stirred-bed reactors (Fig. 8) (125). Unreacted monomer is condensed and recycled to the polymerizer, providing additional removal of the heat of reaction. As in the early Hquid-phase systems, post-reactor treatment of the polymer is required to remove catalyst residues (126). The high content of atactic polymer in the final product limits its usefiilness in many markets. 

As the polymer molecular weight increases, so does the melt viscosity, and the power to the stirrer drive is monitored so that an end point can be determined for each batch. When the desired melt viscosity is reached, the molten polymer is discharged through a bottom valve, often under positive pressure of the blanketing gas, and extmded as a ribbon or as thick strands which are water-quenched and chopped continuously by a set of mechanical knives. Large amounts of PET are also made by continuous polymerization processes. PBT is made both by batch and continuous polymerization processes (79—81). 

EPR and EPDM have been made by either solution or emulsion polymerization processes. More recently a new process involving gas-phase polymerization and metallocene catalysts promises to capture large shares of these markets. These new polymers will be especially attractive in automotive apphcations and wine and cable where theh favorable pricing should be welcome. 

The Phillips-type catalyst can be used in solution polymerization, slurry polymerization, and gas-phase polymerization to produce both high density polyethylene homopolymers and copolymers with olefins such as 1-butene and 1-hexene. The less crystalline copolymers satisfy needs for materials with more suitable properties for certain uses that require greater toughness and flexibiUty, especially at low temperatures. 

Cobalt in Catalysis. Over 40% of the cobalt in nonmetaUic appHcations is used in catalysis. About 80% of those catalysts are employed in three areas (/) hydrotreating/desulfurization in combination with molybdenum for the oil and gas industry (see Sulfurremoval and recovery) (2) homogeneous catalysts used in the production of terphthaUc acid or dimethylterphthalate (see Phthalic acid and otherbenzene polycarboxylic acids) and (i) the high pressure oxo process for the production of aldehydes (qv) and alcohols (see Alcohols, higher aliphatic Alcohols, polyhydric). There are also several smaller scale uses of cobalt as oxidation and polymerization catalysts (44—46). 

As an example of the chemical signihcance of the process technology, the products of die Fischer-Tropsch synthesis, in which a signihcant amount of gas phase polymerization occurs vary markedly from hxed bed operation to the fluidized bed. The hxed bed product contains a higher proportion of straight chain hydrocarbons, and the huidized bed produces a larger proportion of branched chain compounds. 

Chemical incompatibility can manifest itself in many ways however, discussions will be limited to those combinations resulting in fires, explosions, extreme heat, evolution of gas (both toxic and nontoxic), and polymerization. 

Adsorption for gas purification comes under the category of dynamic adsorption. Where a high separation efficiency is required, the adsorption would be stopped when the breakthrough point is reached. The relationship between adsorbate concentration in the gas stream and the solid may be determined experimentally and plotted in the form of isotherms. These are usually determined under static equilibrium conditions but dynamic adsorption conditions operating in gas purification bear little relationship to these results. Isotherms indicate the affinity of the adsorbent for the adsorbate but do not relate the contact time or the amount of adsorbent required to reduce the adsorbate from one concentration to another. Factors which influence the service time of an adsorbent bed include the grain size of the adsorbent depth of adsorbent bed gas velocity temperature of gas and adsorbent pressure of the gas stream concentration of the adsorbates concentration of other gas constituents which may be adsorbed at the same time moisture content of the gas and adsorbent concentration of substances which may polymerize or react with the adsorbent adsorptive capacity of the adsorbent for the adsorbate over the concentration range applicable over the filter or carbon bed efficiency of adsorbate removal required. 

Chemical Reactivity - Reactivity with Water. Reacts violently with water, liberating hydrogen chloride gas and heat Reactivity with Common Materials None if dry. If wet it attacks metals because of hydrochloric acid formed flammable hydrogen is formed Stability During Transport Stable if kept dry and protected from atmospheric moisture Neutralizing Agents for Acids and Caustics Hydrochloric acid formed by reaction with water can be flushed away with water. Rinse with sodium bicarbonate or lime solution Polymerization Not pertinent Inhibitor of Polymerization Not pertinent. 

Chemical Reactivity - Reactivity with Water Reacts violently forming flammable hydrogen gas and a strong caustic solution Reactivity with Common Materials May ignite combustible materials if they are damp or moist Stability During Transport Stable if protected from air and moisture Neutralizing Agents for Acids and Caustics Caustic that is formed by the reaction with water should be flushed with water and then can be rinsed with dilute acetic acid solution Polymerization Not pertinent Inhibitor of Pofymerization Not pertinent. 

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