Separation vinyl acetate monomer process

Figure 5.6 The vinyl acetate monomer plant (Luyben and Tyreus 1998). The reactor-separator process core is highlighted.

Among the observable facts it was found that there is no significant effect of the concentration of emulsifier on this system. Therefore, the implication is that the polymerization initially takes place exclusively in the aqueous phase [136]. The resulting polymer particle precipitates as it forms [134]. In this case we may assume, that only a microscopic phase-separation takes place. The polymer particles which form adsorb emulsifier fiom the aqueous environment and remain dispersed. Then the particles may absorb more monomer somewhat in the manner called for by the Smith-Ewart theory. Of course, other dissolved vinyl acetate monomer molecules may continue to be polymerized in aqueous solution, thus accounting for the increase in the number of particles as the polymerization proceeds to high conversion. The classical Smith-Ewart treatment states that the number of particles is determined by the surfactant to monomer ratio and, in effect remains constant throughout the process. 

Suspension Polymerization. At very low levels of stabilizer, eg, 0.1 wt %, the polymer does not form a creamy dispersion that stays indefinitely suspended in the aqueous phase but forms small beads that setde and may be easily separated by filtration (qv) (69). This suspension or pearl polymerization process has been used to prepare polymers for adhesive and coating appHcations and for conversion to poly(vinyl alcohol). Products in bead form are available from several commercial suppHers of PVAc resins. Suspension polymerizations are carried out with monomer-soluble initiators predominantly, with low levels of stabilizers. Suspension copolymerization processes for the production of vinyl acetate—ethylene bead products have been described and the properties of the copolymers determined (70). Continuous tubular polymerization of vinyl acetate in suspension (71,72) yields stable dispersions of beads with narrow particle size distributions at high yields. 

The PVA process is highly capital-intensive, as separate facilities are required for the production of poly(vinyl acetate), its saponification to PVA, the recovery of unreacted monomer, and the production of acetic acid from the ester formed during alcoholysis. Capital costs are far in excess of those associated with the traditional production of other vinyl resins. 

There are four kinds of polymerization processes bulk, solution, emulsion, and suspension polymerization. As Table 4.7 shows [24], the heat of polymerization of vinyl acetate is high compared to other monomers hence, the control of temperature is difficult in bulk polymerization. In the case of emulsion and suspension polymerization, it is somewhat troublesome to separate dispersed polyvinyl acetate particles from the aqueous medium, and it is necessary to remove the emulsifier and stabilizer completely because these substances induce problems in the process of fiber-making. 

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