Polymerisation processes

Different types of polymerisation processes are employed to obtain polymers from their respective monomers, depending on their suitability for their end applications. These include condensation, addition, ionic, coordination, ring opening, electrochemical and plasma processes. 

The process by which bi-or poly-functional reactants are condensed to form polymer chains with the elimination of small molecules in each condensing step, is known as condensation polymerisation. As the polymer chains are grown incrementally, it may also be called step growth polymerisation. Esterification (direct or ester exchange), amidation, nucleophilic and electrophilic substitution are the general reactions for this polymerisation process. The formation of vegetable oil-based polyester is an example of this type of polymerisation (Fig. 1.1). 

The process by which polymers are formed from their respective monomers by the sequential addition of monomers, without loss of any by-product, is known as addition or chain growth polymerisation. The polymerisation proceeds through three distinct steps  

Initiation, that is the production of reactive species by an initiator, which may be a free radical, cation, or anion. 

Propagation, that is the reactive species reacts with the monomer molecule and transfers its reactivity to another monomer molecule, which is then propagated by transferring this reactivity sequentially to other monomer molecules. 

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The full ab-initio molecular dynamics simulation revealed the insertion of ethylene into the Zr-C bond, leading to propyl formation. The dynamics simulations showed that this first step in ethylene polymerisation is extremely fast. Figure 2 shows the distance between the carbon atoms in ethylene and between an ethylene carbon and the methyl carbon, from which it follows that the insertion time is only about 170 fs. This observation suggests the absence of any significant barrier of activation at this stage of the polymerisation process, and for this catalyst. The absence or very small value of a barrier for insertion of ethylene into a bis-cyclopentadienyl titanocene or zirconocene has also been confirmed by static quantum simulations reported independently... 

Histotically, the classification of PE lesias has developed ia conjunction with the discovery of new catalysts for ethylene polymerisation as well as new polymerisation processes and appHcations. The classification (given ia Table 1) is based on two parameters that could be easily measured ia the 1950s ia a commercial environment with minimum iastmmentation the resia density and its melt iadex. In its present state, this classification provides a simple means for a basic differentiation of PE resias, even though it cannot easily describe some important distinctions between the stmctures and properties of various resia brands. 

A weU-known feature of olefin polymerisation with Ziegler-Natta catalysts is the repHcation phenomenon ia which the growing polymer particle mimics the shape of the catalyst (101). This phenomenon allows morphological control of the polymer particle, particularly sise, shape, sise distribution, and compactness, which greatiy influences the polymerisation processes (102). In one example, the polymer particle has the same spherical shape as the catalyst particle, but with a diameter approximately 40 times larger (96). 

Polymer Production. Three processes are used to produce nylon-6,6. Two of these start with nylon-6,6 salt, a combination of adipic acid and hexamethylenediamine in water they are the batch or autoclave process and the continuous polymerisation process. The third, the soHd-phase polymerisation process, starts with low molecular weight pellets usually made via the autoclave process, and continues to build the molecular weight of the polymer in a heated inert gas, the temperature of which never reaches the melting point of the polymer. 

The polymerisation process proceeds in a manner similar to that of other type AABB polyamides, such as nylon-6,6. The final resin had found apphcation in automotive and other high performance end uses but was withdrawn from the market in 1994. 

D. B. Jacobs and J. Zimmerman, in C. E. Schildknecht and I. Skeist, eds.. Polymerisation Processes, High Polymers, Vol. XXIX. Wiley-Interscience, New York, 1977, pp. 424, 467. A very detailed review of nylon-6,6 polymerization. 

PoIysuIfonyIa.tlon, The polysulfonylation route to aromatic sulfone polymers was developed independendy by Minnesota Mining and Manufacturing (3M) and by Imperial Chemical Industries (ICI) at about the same time (81). In the polymerisation step, sulfone links are formed by reaction of an aromatic sulfonyl chloride with a second aromatic ring. The reaction is similar to the Friedel-Crafts acylation reaction. The key to development of sulfonylation as a polymerisation process was the discovery that, unlike the acylation reaction which requires equimolar amounts of aluminum chloride or other strong Lewis acids, sulfonylation can be accompHshed with only catalytic amounts of certain haUdes, eg, FeCl, SbCl, and InCl. The reaction is a typical electrophilic substitution by an arylsulfonium cation (eq. 13). 

G. D. Cooper and A. YjCiXPSmi2cn.,A.ddition and Condensation Polymerisation Processes, Pidvances in Chemistry Series No. 91, American Chemical Society, Washiagton, D.C., 1969, p. 660. 

Studies have shown that, in marked contrast to carbanionic polymerisation, the reactivity of the free oxonium ion is of the same order of magnitude as that of its ion pair with the counterion (6). On the other hand, in the case of those counterions that can undergo an equiUbrium with the corresponding covalent ester species, the reactivity of the ionic species is so much greater than that of the ester that chain growth by external attack of monomer on covalent ester makes a negligible contribution to the polymerisation process. The relative concentration of the two species depends on the dielectric constant of the polymerisation medium, ie, on the choice of solvent. 

In the late 1920s Bayer Company began reevaluating the emulsion polymerisation process of polybutadiene as an improvement over their Buna technology, which was based on sodium as a catalyst. Incorporation of styrene (qv) as a comonomer produced a superior polymer compared to polybutadiene. The product Buna S was the precursor of the single largest-volume polymer produced in the 1990s, emulsion styrene—butadiene mbber... 

C. E. Schildknecht and I. Skeist, Polymerisation Processes, John Wiley Sons, Inc., New York, 1977. 

In the absence of impurities there is frequently no termination step in anionic polymerisations. Hence the monomer will continue to grow until all the monomer is consumed. Under certain conditions addition of further monomer, even after an interval of several weeks, will eause the dormant polymerisation process to proceed. The process is known as living polymerisation and the products as living polymers. Of particular interest is the fact that the follow-up monomer may be of a different species and this enables block copolymers to be produced. This technique is important with certain types of thermoplastic elastomer and some rather specialised styrene-based plastics. 

Mention has already been made in this chapter of metallocene-catalysed polyethylene (see also Chapter 2). Such metallocene catalysts are transition metal compounds, usually zirconium or titanium. Incorporated into a cyclopentadiene-based structure. During the late 1990s several systems were developed where the new catalysts could be employed in existing polymerisation processes for producing LLDPE-type polymers. These include high pressure autoclave and... 

Bulk polymerisation processes have been known for many years but until the mid-1960s the only commercial process was one operated by Pechiney-St Gobain in France. This process was a one-stage process and according to one patent example vinyl chloride was polymerised with 0.8%% of its own weight of benzoyl peroxide in a rotating cylinder containing steel balls for 17 hours at 58°C. 

In addition, buffer salts such as disodium hydrogen phosphate may be used to prevent the pH of the aqueous phase falling during polymerisation. Small amounts of an anti-foam agent may be employed to reduce frothing when discharging from the vessel at the end of the polymerisation process. 

Poly(vinyl chloride) is commercially available in the form of aqueous colloidal dispersions (latices). They are the uncoagulated products of emulsion polymerisation process and are used to coat or impregnate textiles and paper. The individual particles are somewhat less than 1 p,m in diameter. The latex may be coagulated by concentrated acids, polyvalent cations and by dehydration with water-miscible liquids. 

Since poly(vinyl acetate) is usually used in an emulsion form, the emulsion polymerisation process is commonly used. In a typical system, approximately equal quantities of vinyl acetate and water are stirred together in the presence of a suitable colloid-emulsifier system, such as poly(vinyl alcohol) and sodium lauryl sulphate, and a water-soluble initiator such as potassium persulphate. 

By polymerising styrene in solution many problems associated with heat transfer and the physical movement of viscous masses are reduced, these advantages being offset by problems of solvent recovery and the possibility of chain transfer reactions. In 1955 Distrene Ltd started a plant at Barry in South Wales for the production of styrene by such a solution polymerisation process and some details have been made available. The essential details of this process are indicated by Figure 16.7. 

High molecular weight polymers are produced by an adiabatic bulk polymerisation process ° using di-tert-butyl peroxide (0.02%) and 2,2 -azo-bisdi-isobutyronitrile (0.01%) as initiators and pressurised with N2. Heating to 80-90°C causes an onset of polymerisation and a rapid increase in temperature. After the maximum temperature has been reached the mass is allowed to cool under pressure. A typical current commercial material (Luvican M.170) has a A -value of about 70 (as assessed in a 1% tetrahydrofuran solution). 

Polymers can also be produced by combining two or more different monomers in the polymerisation process. If two monomers are used the product is called a copolymer and the second monomer is usually included in the reaction to enhance the properties of the polymer produced by the first monomer alone. It is possible to control the way in which the monomers (A and B) link up and there are four main configurations which are considered useful. These are ... 

It is commonly found that polymers are less stable particularly to molecular breakdown at elevated temperatures than low molecular weight materials containing similar groupings. In part this may be due to the constant repetition of groups along a chain as discussed above, but more frequently it is due to the presence of weak links along the chain. These may be at the end of the chain (terminal) arising from specific mechanisms of chain initiation and/or termination, or non-terminal and due to such factors as impurities which becomes built into the chain, a momentary aberration in the modus operandi of the polymerisation process, or perhaps, to branch points. 

The initial step of the polymerisation process is reaction of the amine groups with formaldehyde to generate methylol units, as illustrated in Reaction 1.9. Further heating of the polymer then leads to a variety of reactions. For example, the methylol groups can undergo self-condensation (Reaction 1.10). 

Other chain transfer processes may occur. For example, the radical may abstract an atom from along the backbone of a previously formed polymer molecule, and thus initiate the growth of a branch to the main chain. There can also be chain transfer to monomer, which in the nature of the polymerisation process must be a relatively rare phenomenon. However, it can occur infrequently and give rise to a restriction in the size of the polymer molecules without ceasing the overall radical chain reaction. 

Ionic polymerisation is subdivided into cationic and anionic mechanisms depending on the charge developed in the growing polymer molecule. Typical catalysts for the former, the cationic polymerisation process, are Lewis acids such as AICI3 or BFj, which often require a co-catalyst, usually a Lewis base, in order to bring about polymerisation. 

Additionally, our experimental regime now includes extensive use of computer modelling of the polymerisation process and we need to extract chemical, thermal and engineering data for model assembly, verification and for final process improvement. In ICI at Slough we have developed our own approach to the control and data acquisition process used on our semi-technical reactors. 

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