Free radical polymerization processes

Polymerization Processes. Free-radical polymerization is carried out in a variety of ways. One of the practical problems that must be dealt with is mnaway reactions which can result from auto acceleration, an increase in rate of polymerization caused by diffusion-limited termination (reduced... 

Polymerization Processes. Free-radical polymerization is carried out in a variety of ways. 

Polymers can be prepared by many different processes. Free radical polymerization can be accomplished in bulk, suspension, solution, or emulsion. Ionic and other nonradical polymerizations are usually produced in solution polymerizations. Each technique has characteristic advantages and disadvantages. 

This is the initiation step of a free radical polymerization process. Free radical polymerizations, like all addition polymerization reactions, produce head to tail polymerization that is, the growing end of the polymer is the most stable possible radical. In the case of 1,3-butadiene the alkoxy radical attacks an end carbon and not an internal carbon. This is because attack of an end carbon forms a resonance stabilized free radical whereas attack of an internal carbon forms a radical with no such stabilization. Hence, the end carbon will be attacked by the alkoxy radical to form the more stcible species. This is shown as ... 

In the decades after their discovery, radicals were viewed as too reactive for precision synthesis and their reactions were viewed by many chemists as messy, unpredictable, unpromising, and essentially mysterious. ° Despite this initial pessimism, free-radical polymerization rapidly became an important industrial process, responsible for the production of approximately half of all commodity plastics. Compared with other more sophisticated polymerization processes, free-radical polymerization has the often imderstated advantages of being highly robust and versatile, as the neutral radical-hased propagating species is tolerant of a variety of solvent and/ or monomer impurities and can facilitate the (co)polymerization of a wide-airay of monomer... 

Dimerization in concentrated sulfuric acid occurs mainly with those alkenes that form tertiary carbocations In some cases reaction conditions can be developed that favor the formation of higher molecular weight polymers Because these reactions proceed by way of carbocation intermediates the process is referred to as cationic polymerization We made special mention m Section 5 1 of the enormous volume of ethylene and propene production in the petrochemical industry The accompanying box summarizes the principal uses of these alkenes Most of the ethylene is converted to polyethylene, a high molecular weight polymer of ethylene Polyethylene cannot be prepared by cationic polymerization but is the simplest example of a polymer that is produced on a large scale by free radical polymerization... 

The mechanism of free radical polymerization of ethylene is outlined m Figure 6 17 Dissociation of a peroxide initiates the process m step 1 The resulting per oxy radical adds to the carbon-carbon double bond m step 2 giving a new radical which then adds to a second molecule of ethylene m step 3 The carbon-carbon bond forming process m step 3 can be repeated thousands of times to give long carbon chains... 

Free-radical polymerization processes are used to produce virtually all commercial methacrylic polymers. Usually free-radical initiators (qv) such as azo compounds or peroxides are used to initiate the polymerizations. Photochemical and radiation-initiated polymerizations are also well known. At a constant temperature, the initial rate of the bulk or solution radical polymerization of methacrylic monomers is first-order with respect to monomer concentration, and one-half order with respect to the initiator concentration. Rate data for polymerization of several common methacrylic monomers initiated with 2,2 -azobisisobutyronitrile [78-67-1] (AIBN) have been deterrnined and are shown in Table 8. 

The free-radical polymerization of methacrylic monomers follows a classical chain mechanism in which the chain-propagation step entails the head-to-taH growth of the polymeric free radical by attack on the double bond of the monomer. Chain termination can occur by either combination or disproportionation, depending on the conditions of the process (36). 

One of the key benefits of anionic PS is that it contains much lower levels of residual styrene monomer than free-radical PS (167). This is because free-radical polymerization processes only operate at 60—80% styrene conversion, whereas anionic processes operate at >99% styrene conversion. Removal of unreacted styrene monomer from free-radical PS is accompHshed using continuous devolatilization at high temperature (220—260°C) and vacuum. This process leaves about 200—800 ppm of styrene monomer in the product. Taking the styrene to a lower level requires special devolatilization procedures such as steam stripping (168). 

There are two problems in the manufacture of PS removal of the heat of polymeriza tion (ca 700 kj /kg (300 Btu/lb)) of styrene polymerized and the simultaneous handling of a partially converted polymer symp with a viscosity of ca 10 mPa(=cP). The latter problem strongly aggravates the former. A wide variety of solutions to these problems have been reported for the four mechanisms described earlier, ie, free radical, anionic, cationic, and Ziegler, several processes can be used. Table 6 summarizes the processes which have been used to implement each mechanism for Hquid-phase systems. Free-radical polymerization of styrenic systems, primarily in solution, is of principal commercial interest. Details of suspension processes, which are declining in importance, are available (208,209), as are descriptions of emulsion processes (210) and summaries of the historical development of styrene polymerization processes (208,211,212). 

Free-Radical Polymerization. The best method for polymerising isoprene by a free-radical process is emulsion polymerisation. Using potassium persulfate [7727-21-1] as initiator at 50°C, a 75% conversion to polyisoprene in 15 h was obtained (76). A typical emulsion polymerisation recipe is given as follows (77). 

A novel cross-linked polystyrene-divinylbenzene copolymer has been produced from suspension polymerization with toluene as a diluent, having an average particle size of 2 to 50 /rm, with an exclusive molecular weight for the polystyrene standard from about 500 to 20,000 in gel-permeation chromatography. A process for preparing the PS-DVB copolymer by suspension polymerization in the presence of at least one free-radical polymerization initiator, such as 2,2 -azo-bis (2,4-dimethylvaleronitrile) with a half-life of about 2 to 60 min at 70°C, has been disclosed (78). 

Polypropylene made by free-radical polymerization is generally atactic , that is to say, there is no pattern to the stereochemistry. On the other hand, both isotactic polypropylene (in which all the stereocenters are the same) and syndiotactic polypropylene (in which the stereocenters alternate) may be made via the Ziegler-Natta process (see Chapter 18, Problem 4). Experimentally, both isotactic and syndiotactic polypropylene generally have higher melting points than atactic polypropylene. 

Free radical polymerization is a key method used by the polymer industry to produce a wide range of polymers [37]. It is used for the addition polymerization of vinyl monomers including styrene, vinyl acetate, tetrafluoroethylene, methacrylates, acrylates, (meth)acrylonitrile, (meth)acrylamides, etc. in bulk, solution, and aqueous processes. The chemistry is easy to exploit and is tolerant to many functional groups and impurities. 

The previous sections show that certain ionic liquids, namely the chloroalumi-nate(III) ionic liquids, are capable of acting both as catalyst and as solvent for the polymerization of certain olefins, although in a somewhat uncontrolled manner, and that other ionic liquids, namely the non-chloroaluminate(III) ionic liquids, are capable of acting as solvents for free radical polymerization processes. In attempts to carry out polymerization reactions in a more controlled manner, several studies have used dissolved transition metal catalysts in ambient-temperature ionic liquids and have investigated the compatibility of the catalyst towards a range of polymerization systems. 

The most comprehensive simulation of a free radical polymerization process in a CSTR is that of Konopnicki and Kuester (15). For a mechanism which includes transfer to both monomer and solvent as well as termination by combination and disproportionation they examined the influence of non-isothermal operation, viscosity effects as well as induced sinuoidal and square-wave forcing functions on initiator feed and jacket temperature on the MWD of the polymer produced. 

Presented in this paper is a specific example of a semi-batch, free radical, dispersion polymerization. In this example, SimuSolv is used to quantify a Icinetic model derived from free radical polymerization principles and then used to define a new finishing process to reduce residual monomer to an acceptable level. Finally, experimental results are compared with those predicted by the computer simulation. 

STONE Free-Radical Polymerization Finishing Process... 

Free radical polymerization of MMA is a well understood process. The kinetic mechanism neglecting the chain transfer reactions is given as follows (Odian (1970), Rudin (1982)). 

Phosphoranyl radicals can be involved [77] in RAFT processes [78] (reversible addition fragmentation transfer) used to control free radical polymerizations [79]. We have shown [77] that tetrathiophosphoric acid esters are able to afford controlled/living polymerizations when they are used as RAFT agents. This result can be explained by addition of polymer radicals to the P=S bond followed by the selective p-fragmentation of the ensuing phosphoranyl radicals to release the polymer chain and to regenerate the RAFT agent (Scheme 41). 

Yin et al. [73,74] prepared new microgel star amphiphiles and stndied the compression behavior at the air-water interface. Particles were prepared in a two-step process. First, the gel core was synthesized by copolymerization of styrene and divinylbenzene in diox-ane using benzoylperoxide as initiator. Microgel particles 20 run in diameter were obtained. Second, the gel core was grafted with acrylic or methacryUc acid by free radical polymerization, resulting in amphiphilic polymer particles. These particles were spread from a dimethylformamide/chloroform (1 4) solution at the air-water interface. tt-A cnrves indicated low compressibility above lOmNm and collapse pressnres larger than 40 mNm With increase of the hydrophilic component, the molecnlar area of the polymer and the collapse pressure increased. 

Polyalkenes form by linking carbon atoms in a free radical polymerization. The polymer structure is constructed by connecting monomer units. The polymerization process converts the bonds of the monomers to a bonds between polymer repeat units. 

A discussion of ligand exchange reactions of organometallic compounds associated with oxidation-reduction processes leading to free-radical formation will be found in Volume 14 (Free-radical polymerization). 

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