Hydrocarbon solvents, polymerization

The diene monomers give predominantly 1,4-polymers in hydrocarbon solvents if polymerized using lithium-based initiation. Isoprene, under these conditions, gives a predominantly cis-1,4 polymer but with butadiene the proportions of cis- and frans-1,4 are fairly evenly distributed. Once ain this phenomenon is characteristic of lithium compounds sodium- and potassium-based initiation gives mixed structures even in hydrocarbon solvents. Polymerization in polar solvents such as tetrahydrofuran leads to largely 3,4-polyisoprene or 1,2-butadiene with... 

Polyacetaldehyde, a mbbery polymer with an acetal stmcture, was first discovered in 1936 (49,50). More recentiy, it has been shown that a white, nontacky, and highly elastic polymer can be formed by cationic polymerization using BF in Hquid ethylene (51). At temperatures below —75° C using anionic initiators, such as metal alkyls in a hydrocarbon solvent, a crystalline, isotactic polymer is obtained (52). This polymer also has an acetal [poly(oxymethylene)] stmcture. Molecular weights in the range of 800,000—3,000,000 have been reported. Polyacetaldehyde is unstable and depolymerizes in a few days to acetaldehyde. The methods used for stabilizing polyformaldehyde have not been successful with poly acetaldehyde and the polymer has no practical significance (see Acetalresins). 

Anionic polymerization of vinyl monomers can be effected with a variety of organometaUic compounds alkyllithium compounds are the most useful class (1,33—35). A variety of simple alkyllithium compounds are available commercially. Most simple alkyllithium compounds are soluble in hydrocarbon solvents such as hexane and cyclohexane and they can be prepared by reaction of the corresponding alkyl chlorides with lithium metal. Methyllithium [917-54-4] and phenyllithium [591-51-5] are available in diethyl ether and cyclohexane—ether solutions, respectively, because they are not soluble in hydrocarbon solvents vinyllithium [917-57-7] and allyllithium [3052-45-7] are also insoluble in hydrocarbon solutions and can only be prepared in ether solutions (38,39). Hydrocarbon-soluble alkyllithium initiators are used directiy to initiate polymerization of styrene and diene monomers quantitatively one unique aspect of hthium-based initiators in hydrocarbon solution is that elastomeric polydienes with high 1,4-microstmcture are obtained (1,24,33—37). Certain alkyllithium compounds can be purified by recrystallization (ethyllithium), sublimation (ethyllithium, /-butyUithium [594-19-4] isopropyllithium [2417-93-8] or distillation (j -butyUithium) (40,41). Unfortunately, / -butyUithium is noncrystaUine and too high boiling to be purified by distiUation (38). Since methyllithium and phenyllithium are crystalline soUds which are insoluble in hydrocarbon solution, they can be precipitated into these solutions and then redissolved in appropriate polar solvents (42,43). OrganometaUic compounds of other alkaU metals are insoluble in hydrocarbon solution and possess negligible vapor pressures as expected for salt-like compounds. 

From the time that isoprene was isolated from the pyrolysis products of natural mbber (1), scientific researchers have been attempting to reverse the process. In 1879, Bouchardat prepared a synthetic mbbery product by treating isoprene with hydrochloric acid (2). It was not until 1954—1955 that methods were found to prepare a high i i -polyisoprene which dupHcates the stmcture of natural mbber. In one method (3,4) a Ziegler-type catalyst of tri alkyl aluminum and titanium tetrachloride was used to polymerize isoprene in an air-free, moisture-free hydrocarbon solvent to an all i7j -l,4-polyisoprene. A polyisoprene with 90% 1,4-units was synthesized with lithium catalysts as early as 1949 (5). 

Other Organolithium Compounds. Organoddithium compounds have utiHty in anionic polymerization of butadiene and styrene. The lithium chain ends can then be converted to useflil functional groups, eg, carboxyl, hydroxyl, etc (139). Lewis bases are requHed for solubdity in hydrocarbon solvents. 

Polymerization in Solution or Slurry. Many hydrocarbon solvents dissolve PE at elevated temperatures of 120—150°C. Polymerization reactions in solution requite, as theit last step, the stripping of solvent. A variety of catalysts can be used in these processes. 

Eastman Chemical has utilized a unique, high temperature solution process for propylene polymerization. Polymerization temperatures are maintained above 150°C to prevent precipitation of the isotactic polypropylene product in the hydrocarbon solvent. At these temperatures, the high rate of polymerization decreases rapidly, requiring low residence times (127). Stereoregularity is also adversely affected by high temperatures. Consequentiy, the... 

Reaction and Heat-Transfer Solvents. Many industrial production processes use solvents as reaction media. Ethylene and propylene are polymerized in hydrocarbon solvents, which dissolves the gaseous reactant and also removes the heat of reaction. Because the polymer is not soluble in the hydrocarbon solvent, polymer recovery is a simple physical operation. Ethylene oxide production is exothermic and the catalyst-filled reaction tubes are surrounded by hydrocarbon heat-transfer duid. 

The polymeric acyl titanate esters are viscous Hquids or waxes that are soluble ia hydrocarbon solvents and can be used as Ti02-dispersiag agents, water-repellent agents for textile fabrics, and mst inhibitors for steel. 

Alkali Metal Catalysts. The polymerization of isoprene with sodium metal was reported in 1911 (49,50). In hydrocarbon solvent or bulk, the polymerization of isoprene with alkaU metals occurs heterogeneously, whereas in highly polar solvents the polymerization is homogeneous (51—53). Of the alkah metals, only lithium in bulk or hydrocarbon solvent gives over 90% cis-1,4 microstmcture. Sodium or potassium metals in / -heptane give no cis-1,4 microstmcture, and 48—58 mol % /ram-1,4, 35—42% 3,4, and 7—10% 1,2 microstmcture (46). Alkali metals in benzene or tetrahydrofuran with crown ethers form solutions that readily polymerize isoprene however, the 1,4 content of the polyisoprene is low (54). For example, the polyisoprene formed with sodium metal and dicyclohexyl-18-crown-6 (crown ether) in benzene at 10°C contains 32% 1,4-, 44% 3,4-, and 24% 1,2-isoprene units (54). 

Ah these polymerizations proceed only in the absence of oxygen or water, which react with the highly reactive propagating species. Polymerization is usuahy carried out in an inert, hydrocarbon solvent and under a nitrogen blanket. Under these conditions, polymers with narrow molecular-weight distributions and precise molecular weights can be produced in stoichiometric amounts. 

Studies in the photoinitiation of polymerization by transition metal chelates probably stem from the original observations of Bamford and Ferrar [33]. These workers have shown that Mn(III) tris-(acety]acetonate) (Mn(a-cac)3) and Mn (III) tris-(l,l,l-trifluoroacetyl acetonate) (Mn(facac)3) can photosensitize the free radical polymerization of MMA and styrene (in bulk and in solution) when irradiated with light of A = 365 at 25°C and also abstract hydrogen atom from hydrocarbon solvents in the absence of monomer. The initiation of polymerization is not dependant on the nature of the monomer and the rate of photodecomposition of Mn(acac)3 exceeds the rate of initiation and the initiation species is the acac radical. The mechanism shown in Scheme (14) is proposed according to the kinetics and spectral observations ... 

Fig. 3. Comparison of the rates of polymerization by one-component and two-component catalysts (75°C, ethylene pressure 5.5 kg/cm2, polymerization in hydrocarbon solvent). Curve 1—TiCh (specific surface 24 m /g). Curve 2—TiCfi + AlEtjCl (Al Ti = 4, specific surface of TiClj 20 m2/g the same sample of TiClj was used for the preparation of TiCls). Curve 3—TiCfi + AlEtjCl (Al Ti = 4).

Manufacture of highly water-absorbent polymers with uniform particle size and good flowability can be carried out by reverse phase suspension polymerization of (meth)acrylic acid monomers in a hydrocarbon solvent containing crosslinker and radical initiator. Phosphoric acid monoester or diester of alka-nole or ethoxylated alkanole is used as surfactant. A polymer with water-absorbent capacity of 78 g/g polymer can be obtained [240]. 

The difficulties encountered in the early studies of anionic polymerization of methyl methacrylate arose from the unfortunate choice of experimental conditions the use of hydrocarbon solvents and of lithium alkyl initiators. The latter are strong bases. Even at —60 °C they not only initiate the conventional vinyl poly-addition, but attack also the ester group of the monomer yielding a vinyl ketone1, a very reactive monomer, and alkoxide 23). Such a process is described by the scheme. 

Polymerization of t-butyl methacrylate initiated by lithium compounds in toluene yields 100% isotactic polymers 64,65), and significantly, of a nearly uniform molecular-weight, while the isotactic polymethyl methacrylate formed under these conditions has a bimodal distribution. Significantly, the propagation of the lithium pairs of the t-Bu ester carbanion, is faster in toluene than in THF. In hydrocarbon solvents the monomers seem to interact strongly with the Li+ cations in the transition state of the addition, while the conventional direct monomer interaction with carbanions, that requires partial dissociation of ion-pair in the transition state of propagation, governs the addition in ethereal solvents. 

The mechanism of anionic polymerization of styrene and its derivatives is well known and documented, and does not require reviewing. Polymerization initiated in hydrocarbon solvents by lithium alkyls yields dimeric dormant polymers, (P, Li)2, in equilibrium with the active monomeric chains, P, Li, i.e. 

An interesting approach to studies of the effects of coordination on the reactivity of lithium polydienes in hydrocarbon solvents was developed by Erussalimski and his colleagues 151 154 The polymerization of lithium polyisoprene in hexane is accelerated by the addition of TMEDA152), the rate levels off at a value of R = [TMEDA]/[li-thium polyisoprene] of 8, its final value giving the absolute rate constant of propagation of the polyisoprene coordinated with TMEDA, namely 0.17 M7l s at 20 °C. 

Tg=—88 Amorphous, except for polymers prepared by free radical polymerization at 0°C or lower. Latter crystallize on cooling or stretching. Soft rubbery. Generally contains gel fraction insoluble even in hydrocarbon solvents... 

Reciprocal degrees of polymerization of polystyrenes prepared by thermal polymerization at 100°C in hydrocarbon solvents are plotted against [>8]/[itf] in Fig. 16. Conversions were sufficiently low to permit the assumption of constancy in this ratio, which is taken equal to its initial value. The linearity of plots such as these, including those for numerous other monomer-solvent pairs which have been investigated, affords the best confirmation for the widespread occurrence of chain transfer and for the bimolecular mechanisms assumed. It is... 

Fig. 16.—Effects of several hydrocarbon solvents on the degree of polymerization of styrene at 100°C. (Gregg and Mayo." )...

The kinetic model describes the carbanion polymerization of styrene in a hydrocarbon solvent using n-butyl lithium as the initiator. The mechanism is characterized by four steps ... 

A detailed study of the mechanism of the insertion reaction of monomer between the metal-carbon bond requires quantitative information on the kinetics of the process. For this information to be meaningful, studies should be carried out on a homogeneous system. Whereas olefins and compounds such as Zr(benzyl)4 and Cr(2-Me-allyl)3, etc. are very soluble in hydrocarbon solvents, the polymers formed are crystalline and therefore insoluble below the melting temperature of the polyolefine formed. It is therefore not possible to use olefins for kinetic studies. Two completely homogeneous systems have been identified that can be used to study the polymerization quantitatively. These are the polymerization of styrene by Zr(benzyl)4 in toluene (16, 25) and the polymerization of methyl methacrylate by Cr(allyl)3 and Cr(2-Me-allyl)3 (12)- The latter system is unusual since esters normally react with transition metal allyl compounds (10) but a-methyl esters such as methyl methacrylate do not (p. 270) and the only product of reaction is polymethylmethacrylate. Also it has been shown with both systems that polymerization occurs without a change in the oxidation state of the metal. 

Anionic polymerization can be initiated by a variety of anionic sources such as metal alkoxides, aryls, and alkyls. Alkyllithium initiators are among the most useful, being employed commercially in the polymerization of 1,3-butadiene and isoprene, due to their solubility in hydrocarbon solvents. Initiation involves addition of alkyl anion to monomer... 

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