Polymerization temperature control

The properties and usefulness of the final polymer depend on its structure and can be directed by appropriate control of process variables during polymerization. Temperature control and the choice of catalyst are critical in minimizing the side reactions, such as formation of carboxyl end groups by elimination of tetrahydrofuran (THE) from 4-hydroxybutyl ester end groups. The proper choice of co-catalyst could promote direct polycondensation reaction with less extent of side reactions. For example, tetrapropyl zirconate is known as an efficient co-catalyst [23]. The temperature and pressure are also significantly important in controlling the rate of polycondensation reaction and degradation. 

Chain transfer and control of molecular weight are mediated by the activation energy of head-to-head addition, and thus by polymerization temperature alone. PVC is the only major commercial polymer wherein polymerization temperature controls molecular weight and molecular weight distribution. 

Initiators. The degree of polymerization is controlled by the addition rate of initiator(s). Initiators (qv) are chosen primarily on the basis of half-life, the time required for one-half of the initiator to decay at a specified temperature. In general, initiators of longer half-Hves are chosen as the desired reaction temperature increases they must be well dispersed in the reactor prior to the time any substantial reaction takes place. When choosing an initiator, several factors must be considered. For the autoclave reactor, these factors include the time permitted for completion of reaction in each zone, how well the reactor is stirred, the desired reaction temperature, initiator solubiUty in the carrier, and the cost of initiator in terms of active oxygen content. For the tubular reactors, an additional factor to take into account is the position of the peak temperature along the length of the tube (9). 

Catalyst Development. Traditional slurry polypropylene homopolymer processes suffered from formation of excessive amounts of low grade amorphous polymer and catalyst residues. Introduction of catalysts with up to 30-fold higher activity together with better temperature control have almost eliminated these problems (7). Although low reactor volume and available heat-transfer surfaces ultimately limit further productivity increases, these limitations are less restrictive with the introduction of more finely suspended metallocene catalysts and the emergence of industrial gas-phase fluid-bed polymerization processes. 

At the same time, however, considerable research was being done, especially in Germany, on a novel process called emulsion polymerization, in which the monomer was polymerized as an emulsion in the presence of water and soap. This seemed advantageous since the product appeared as a latex, just like natural mbber, leading to low viscosity even at high soHds content, while the presence of the water assured better temperature control. The final result, based mainly on work at the LG. Farbenindustrie (IGF) (10), was the development of a butadiene—styrene copolymer prepared by emulsion polymerization, the foremnner of the present-day leading synthetic mbber, SBR. 

In the recipes shown in Table 2, the amount of water can vary widely, depending on the available heat-transfer capacity of the reactor and the rate of polymerization. Each of the monomers has a heat of polymerization of about 75 kj/ mol (18 kcal/mol), so removing the heat of polymerization to control temperature is often the limiting factor on rate of polymerization. 

Bead Polymerization Bulk reaction proceeds in independent droplets of 10 to 1,000 [Lm diameter suspended in water or other medium and insulated from each other by some colloid. A typical suspending agent is polyvinyl alcohol dissolved in water. The polymerization can be done to high conversion. Temperature control is easy because of the moderating thermal effect of the water and its low viscosity. The suspensions sometimes are unstable and agitation may be critical. Only batch reaciors appear to be in industrial use polyvinyl acetate in methanol, copolymers of acrylates and methacrylates, polyacrylonitrile in aqueous ZnCh solution, and others. Bead polymerization of styrene takes 8 to 12 h. 

A semi-batch reactor has the same disadvantages as the batch reactor. However, it has the advantages of good temperature control and the capability of minimizing unwanted side reactions by maintaining a low concentration of one of the reactants. Semi-batch reactors are also of value when parallel reactions of different orders occur, where it may be more profitable to use semi-batch rather than batch operations. In many applications semi-batch reactors involve a substantial increase in the volume of reaction mixture during a processing cycle (i.e., emulsion polymerization). 

Catala and coworkers167JuiS made the discovery that the rate of TEMPO-mediated polymerization of S is independent of the concentration of the alkoxyamine. This initially surprising result was soon confirmed by others.23 69 Gretza and Matyjaszewski169 showed that the rate of NMP is controlled by the rate of thermal initiation. With faster decomposing alkoxyamines (those based on the open-chain nitroxides) at lower polymerization temperatures, the rate of thermal initiation is lower such that the rate of polymerization becomes dependent on the alkoxyamine concentration, Irrespective of whether the alkoxyamine initiator is preformed or formed in situ, low dispersities require that the alkoxyamine initiator should have a short lifetime. The rate of initiation should be as fast as or faster than propagation under the polymerization conditions and lifetimes of the alkoxyamine initiators should be as short as or shorter than individual polymeric alkoxyamines. 

While our primary objective of developing conditions for the LC Pzn of P-PIN has not been reached, a simple route to relatively high molecular weight product (at least up to 40,000) was found. Experiments described in this communication also demonstrate that the molecular weight of poly(P-PIN) can be controlled by the polymerization temperature. 

The advantage of suspension processes over mass processes is the excellent temperature control that can be obtained through the suspending medium, water. This allows for rapid heat removal and shorter polymerization times. It reduces or eliminates hot spots or heat-kicks characteristic of mass reactors. It also allows the polymerization to be driven very close to completion so that no devolatilization step is normally required. 

By maintaining the first-stage reactor just beyond the phase inversion point, the dispersed rubber phase is relatively rich in dissolved styrene. As polymerization subsequently proceeds in the LFR s, the dissolved styrene will react to form either a graft copolymer with the rubber or a homopolymer. The latter will remain within the rubber droplet as a separate occluded phase. Achieving the first-stage reactor conversion and temperature by recycling a portion of the hot second reactor effluent may permit simplification of the first reactor temperature control system. 

The maximum rate of polymerization has been confirmed to occur at the laminar-turbulent flow transition. The rate of polymerization was observed to be maximum at the transition for both straight reactors as well as for the helically-coiled reactor for which the transition is at a Reynolds number higher than that of the straight tube. The helically coiled tubular reactor is of industrial interest since it is much more compact and, consequently, the cost and the temperature control problems are more tractable. 

Polymerization. Isothermal polymerizations were conducted in 1/8" molds controlled at the stated isothermal temperature. Below lOO C circulating water was the temperature control medium whereas circulating air was used above 100 C. Reactants were... 

Equation (l) shows the rate of polymerization is controlled by the radical concentration and as described by Equation (2) the rate of generation of free radicals is controlled by the initiation rate. In addition. Equation (3) shows this rate of generation is controlled by the initiator and initiator concentration. Further, the rate of initiation controls the rate of propagation which controls the rate of generation of heat. This combined with the heat transfer controls the reaction temperature and the value of the various reaction rate constants of the kinetic mechanism. Through these events it becomes obvious that the initiator is a prime control variable in the tubular polymerization reaction system. 

There is a middle steady state, but it is metastable. The reaction will tend toward either the upper or lower steady states, and a control system is needed to maintain operation around the metastable point. For the styrene polymerization, a common industrial practice is to operate at the metastable point, with temperature control through autorefrigeration (cooling by boiling). A combination of feed preheating and jacket heating ensures that the uncontrolled reaction would tend toward the upper, runaway condition. However,... 

Thermal runaway. Temperature control in a tubular polymerizer depends on convective diffusion of heat. This becomes difficult in a large-diameter tube, and temperatures may rise to a point where a thermal runaway becomes inevitable. 

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