Polymerization processes high pressure

Abstract Molecular spectroscopy is one of the most important means to characterize the various species in solid, hquid and gaseous elemental sulfur. In this chapter the vibrational, UV-Vis and mass spectra of sulfur molecules with between 2 and 20 atoms are critically reviewed together with the spectra of liquid sulfur and of solid allotropes including polymeric and high-pressure phases. In particular, low temperature Raman spectroscopy is a suitable technique to identify single species in mixtures. In mass spectra cluster cations with up to 56 atoms have been observed but fragmentation processes cause serious difficulties. The UV-Vis spectra of S4 are reassigned. The modern XANES spectroscopy has just started to be applied to sulfur allotropes and other sulfur compounds. 

Polymerization of methyl methacrylate to Plexiglas is done in the bulk process. High pressure polymerization of ethylene is done this way also. But other addition polymerizations frequently become too exothermic and without adequate heat removal system, the reaction tends to run away from optimum conditions. 

LDPE was occasionally found in 1933 by R.O. Gibson and E.W. Fawcett, when they tried to perform reactions with ethylene [1]. Based on their invention. Imperial Chemicals Ltd (ICI), Great Britain, developed a process with a stirred autoclave in which ethylene was radically polymerized under high pressure [2], Later, BASF AG in Germany designed a tubular reactor to produce LDPE under similar high-pressure conditions [3]. 

The most favorable conditions for reactive processing of monolithic articles are created when the frontal reaction occurs at a plane thermal front. For example, a frontal process can be used for methyl methacrylate polymerization at high pressure (up to 500 MPa) in the presence of free-radical initiators. The reaction is initiated by an initial or continuous local increase in temperature of the reactive mass in a stationary mold, or in a reactor if the monomer is moving through a reactor. The main method of controlling the reaction rate and maintaining stability is by varying the temperature of the reactive mass.252... 

The physical transport of the reactor products may also need sufficient processing. Bulk polymerizations in high-pressure extruders may be followed by dicing the product into small pellets suitable for pneumatic transport. Emulsion and solution products are usually transported as obtained and frequently used in the same mode. The design of suitable containers and transportation protocols is very important to avoid harming the product during transportation and storage. For example, special containers may be required for air-sensitive materials, or to avoid solvent or water loss from solutions and emulsions, respectively. 

Discovery of Linear (High-Density) Polyethylene Use of Comonomers Linear Low-Density Polyethylene Stereospecific Polymerization Discovery of Polypropylene Manufacturing Processes High-Pressure LDPE Low-Pressure, Linear HOPE LLDPE... 

Fr00-Radical Procass. The first commercial PE was developed by Imperial Chemical Industries from 1932 to 1938 using a free-radical process (12). Ethylene was polymerized at high pressure (142 MPa or 1400 atm) and at about 180°C. It was discovered by accident that oxygen impurity could serve as the initiator. An ICI British patent filed in 1936 (13) disclosed pressures of ca 50-300 MPa (500-3000 atm), temperatures of 100-300°C, the necessity of removing heat to control temperature, and the necessity of controlling the oxygen content of the ethylene used. 

A schematic of a continuous bulk SAN polymerization process is shown in Figure 4 (90). The monomers are continuously fed into a screw reactor where copolymerization is carried out at 150°C to 73% conversion in 55 min. Heat of polymerization is removed through cooling of both the screw and the barrel walls. The polymeric melt is removed and fed to the devolatilizer to remove unreacted monomers under reduced pressure (4 kPa or 30 mm Hg) and high temperature (220°C). The final product is claimed to contain less than 0.7% volatiles. Two devolatilizers in series are found to yield a better quaUty product as well as better operational control (91,92). 

The second type of solution polymerization concept uses mixtures of supercritical ethylene and molten PE as the medium for ethylene polymerization. Some reactors previously used for free-radical ethylene polymerization in supercritical ethylene at high pressure (see Olefin POLYMERS,LOW DENSITY polyethylene) were converted for the catalytic synthesis of LLDPE. Both stirred and tubular autoclaves operating at 30—200 MPa (4,500—30,000 psig) and 170—350°C can also be used for this purpose. Residence times in these reactors are short, from 1 to 5 minutes. Three types of catalysts are used in these processes. The first type includes pseudo-homogeneous Ziegler catalysts. In this case, all catalyst components are introduced into a reactor as hquids or solutions but form soHd catalysts when combined in the reactor. Examples of such catalysts include titanium tetrachloride as well as its mixtures with vanadium oxytrichloride and a trialkyl aluminum compound (53,54). The second type of catalysts are soHd Ziegler catalysts (55). Both of these catalysts produce compositionaHy nonuniform LLDPE resins. Exxon Chemical Company uses a third type of catalysts, metallocene catalysts, in a similar solution process to produce uniformly branched ethylene copolymers with 1-butene and 1-hexene called Exact resins (56). 

Polymerization in Hquid monomer was pioneered by RexaH Dmg and Chemical and Phillips Petroleum (United States). In the RexaH process, Hquid propylene is polymerized in a stirred reactor to form a polymer slurry. This suspension is transferred to a cyclone to separate the polymer from gaseous monomer under atmospheric pressure. The gaseous monomer is then compressed, condensed, and recycled to the polymerizer (123). In the Phillips process, polymerization occurs in loop reactors, increasing the ratio of available heat-transfer surface to reactor volume (124). In both of these processes, high catalyst residues necessitate post-reactor treatment of the polymer. 

Ammonia is used in the fibers and plastic industry as the source of nitrogen for the production of caprolactam, the monomer for nylon 6. Oxidation of propylene with ammonia gives acrylonitrile (qv), used for the manufacture of acryHc fibers, resins, and elastomers. Hexamethylenetetramine (HMTA), produced from ammonia and formaldehyde, is used in the manufacture of phenoHc thermosetting resins (see Phenolic resins). Toluene 2,4-cHisocyanate (TDI), employed in the production of polyurethane foam, indirectly consumes ammonia because nitric acid is a raw material in the TDI manufacturing process (see Amines Isocyanates). Urea, which is produced from ammonia, is used in the manufacture of urea—formaldehyde synthetic resins (see Amino resins). Melamine is produced by polymerization of dicyanodiamine and high pressure, high temperature pyrolysis of urea, both in the presence of ammonia (see Cyanamides). 

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). 

A more recent development in ethylene polymerization is the simplified low pressure LDPE process. The pressure range is 0.7—2.1 MPa with temperatures less than 100°C. The reaction takes place in the gas phase instead of Hquid phase as in the conventional LDPE technology. These new technologies demand ultra high purity ethylene. 

In the production of a-olefins, ethylene reacts with an aluminum alkyl at relatively low temperature to produce a higher aLkylalumiaum. This is then subjected to a displacement reaction with ethylene at high temperatures to yield a mixture of a-olefins and triethylalumiaum. In an alternative process, both reactions are combiaed at high temperatures and pressures where triethylalumiaum fuactioas as a catalyst ia the polymerization process. 

Polymerization Exothermic reaction which, unless carefully controlled, can run-away and create a thermal explosion or vessel overpressurization Refer to Table 7.20 for common monomers Certain processes require polymerization of feedstock at high pressure, with associated hazards Many vinyl monomers (e.g. vinyl chloride, acrylonitrile) pose a chronic toxicity hazard Refer to Table 7.19 for basic precautions... 

The reaction section consists of the high pressure reactors filled with catalyst, and means to take away or dissipate the high heat of reaction (300-500 Btu/lb of olefin polymerized). In the tubular reactors, the catalyst is inside a multiplicity of tubes which are cooled by a steam-water condensate jacket. Thus, the heat of reaction is utilized to generate high pressure steam. In the chamber process, the catalyst is held in several beds in a drum-type reactor with feed or recycled product introduced as a quench between the individual beds. 

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