Methyl methacrylate high-conversion

Only with propanal are very high conversions (99%) and selectivity (> 98 0) to MMA and MAA possible at this time. Although nearly 95% selective, the highest reported conversions with propionic acid or methyl propionate are only 30—40%. This results in large recycle streams and added production costs. The propanal route suffers from the added expense of the additional step required to oxidize methacrolein to methacrylic acid. 

The chemical resistance and excellent light stabiUty of poly(methyl methacrylate) compared to two other transparent plastics is illustrated in Table 5 (25). Methacrylates readily depolymerize with high conversion, ie, 95%, at >300° C (1,26). Methyl methacrylate monomer can be obtained in high yield from mixed polymer materials, ie, scrap. 

Bulk Polymerization. This is the method of choice for the manufacture of poly(methyl methacrylate) sheets, rods, and tubes, and molding and extmsion compounds. In methyl methacrylate bulk polymerization, an auto acceleration is observed beginning at 20—50% conversion. At this point, there is also a corresponding increase in the molecular weight of the polymer formed. This acceleration, which continues up to high conversion, is known as the Trommsdorff effect, and is attributed to the increase in viscosity of the mixture to such an extent that the diffusion rate, and therefore the termination reaction of the growing radicals, is reduced. This reduced termination rate ultimately results in a polymerization rate that is limited only by the diffusion rate of the monomer. Detailed kinetic data on the bulk polymerization of methyl methacrylate can be found in Reference 42. 

The performance of many metal-ion catalysts can be enhanced by doping with cesium compounds. This is a result both of the low ionization potential of cesium and its abiUty to stabilize high oxidation states of transition-metal oxo anions (50). Catalyst doping is one of the principal commercial uses of cesium. Cesium is a more powerflil oxidant than potassium, which it can replace. The amount of replacement is often a matter of economic benefit. Cesium-doped catalysts are used for the production of styrene monomer from ethyl benzene at metal oxide contacts or from toluene and methanol as Cs-exchanged zeofltes ethylene oxide ammonoxidation, acrolein (methacrolein) acryflc acid (methacrylic acid) methyl methacrylate monomer methanol phthahc anhydride anthraquinone various olefins chlorinations in low pressure ammonia synthesis and in the conversion of SO2 to SO in sulfuric acid production. 

In the literature there is only one serious attempt to develop a detailed mechanistic model of free radical polymerization at high conversions (l. > ) This model after Cardenas and 0 Driscoll is discussed in some detail pointing out its important limitations. The present authors then describe the development of a semi-empirical model based on the free volume theory and show that this model adequately accounts for chain entanglements and glassy-state transition in bulk and solution polymerization of methyl methacrylate over wide ranges of temperature and solvent concentration. 

Balke, S.T., "The Free Radical Polymerization of Methyl Methacrylate to High Conversion", Ph.D. Thesis, McMaster University, Hamilton, Ontario (1972). 

Figure 9 shows the result of injecting 10 gA of the total low molecular weight fraction from GPC 1 (Column Code A2) into GPC 2 (Column Code Bl). With this column code, GPC 2 is performing as a High Performance Liquid Chromatograph (HPLC). Separation is based upon solubility (i.e. composition differences) rather than upon molecular size. Methyl methacrylate monomer was used as a reference and added to the solution injected into GPC 1. Concentrations of n-butyl methacrylate, styrene and conversion are readily calculated from the peak areas and initial concentrations. 

Bauer et al. describe the use of a noncontact probe coupled by fiber optics to an FT-Raman system to measure the percentage of dry extractibles and styrene monomer in a styrene/butadiene latex emulsion polymerization reaction using PLS models [201]. Elizalde et al. have examined the use of Raman spectroscopy to monitor the emulsion polymerization of n-butyl acrylate with methyl methacrylate under starved, or low monomer [202], and with high soUds-content [203] conditions. In both cases, models could be built to predict multiple properties, including solids content, residual monomer, and cumulative copolymer composition. Another study compared reaction calorimetry and Raman spectroscopy for monitoring n-butyl acrylate/methyl methacrylate and for vinyl acetate/butyl acrylate, under conditions of normal and instantaneous conversion [204], Both techniques performed well for normal conversion conditions and for overall conversion estimate, but Raman spectroscopy was better at estimating free monomer concentration and instantaneous conversion rate. However, the authors also point out that in certain situations, alternative techniques such as calorimetry can be cheaper, faster, and often easier to maintain accurate models for than Raman spectroscopy, hi a subsequent article, Elizalde et al. found that updating calibration models after... 

The initiation process appears more complicated than described above, although data are not available in more than a few systems. The benzoyl peroxide initiated polymerization of styrene involves considerable substitution of initiator radicals on the benzene ring for polymerizations carried out at high conversions and high initiator concentrations. About one-third of the initiator radicals from t-butyl peroxide abstract hydrogen atoms from the a-methyl groups of methyl methacrylate, while there is no such abstraction for initiator radicals from benzoyl peroxide or AIBN. 

Because of the experimental difficulties involved, there are relatively few reliable Cp values available in the literature. The values that are available [Eastmond, 1976a,b,c Ham, 1967] for any one polymer often vary considerably from each other. It is often most useful to consider the small model compound analog of a polymer (e.g., ethylbenzene or isopropylbenzene for polystyrene) to gain a correct perspective of the importance of polymer chain transfer. A consideration of the best available Cp values and those of the appropriate small-model compounds indicates that the amount of transfer to polymer will not be high in most cases even at high conversion. Cp values are about 10-4 or slightly higher for many polymers such as polystyrene and poly(methyl methacrylate). 

Case 3 behavior occurs when the particle size is sufficiently large (about 0.1-1 pm) relative to kt such that two or more radicals can coexist in a polymer particle without instantaneous termination. This effect is more pronounced as the particle size and percent conversion increase. At high conversion the particle size increases and k, decreases, leading to an increase in h. The increase in h occurs at lower conversions for the larger-sized particles. Thus for styrene polymerization it increases from 0.5 to only 0.6 at 90% conversion for 0.7-pm particles. On the other hand, for 1.4-pm particles, n increases to about 1 at 80% conversion and more than 2 at 90% conversion [Chatterjee et al., 1979 Gerrens, 1959]. Much higher values of h have been reported in other emulsion polymerizations [Ballard et al., 1986 Mallya and Plamthottam, 1989]. Methyl methacrylate has a more pronounced Trommsdorff effect than styrene and vinyl acetate, and this results in a more exaggerated tendency toward case 3 behavior for methyl methacrylate. 

In such cases the polymerization can be taken to relatively high conversion without change in composition of the copolymer formed (see Example 3-37). In the copolymerization diagram the azeotrope corresponds to the intersection point of the copolymerization curve with the diagonal. For example, from Fig. 3.4 it may be seen that in the radical copolymerization of styrene and methyl methacrylate the azeotropic composition corresponds to 53 mol% of styrene. 

Mastication of extracted natural rubber with methyl methacrylate in an extruder gives a relatively high conversion of monomers, >60%, and the formation of a modified rubber (97). 

Since Schultz (7) found that ultimate conversion depended considerably on temperature (in a highly polymerized methyl methacrylate system), similar effects would be expected in the postirradiation-heating of the PVC-styrene system. Such effects have indeed been found. Figure 4 shows the effect of heating temperature on the conversion level at two different radiation doses. No increased conversion is found for a temperature higher than 75 °C. This seems to indicate that a more or less definite melting point of the partially polymerized mixture exists. When this temperature is reached during the postirradiation treatment, the reaction runs to a point of termination and is unaffected by further temperature increases. 

It should be noted here that, when free radical polymerizations were carried out under an electric field using methyl methacrylate which had deliberately been allowed to absorb water, the polymerizing solutions showed high electric conductivity and gave lower conversion and degree of polymerization than in the absence of the electric field (11). The low... 

Although quantitative areas for all absorptions can not be obtained from a single spectrum, an assumption that a —C=0 group adjacent to a C=C bond has similar relaxation times, and hence they have comparable peak, area is made. Based on this assumption the conversion of various multifunctional monomers, which yield highly crosslinked polymers with methyl methacrylate, is determined from the spectra recorded at 1 ms contact time. It is also found that the conversion of these comonomers increases with the increasing length and flexibility of the spacer between the methacrylate double bonds 245). 

HI 1. Hwa, J. C. H. Measurements on the degree of crosslinking of high-conversion post-gelation methyl methacrylate-methylene dimethacrylate copolymers. J. Polymer Sci. 58, 715 (1962). 

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