Solution processability

Although the data for the silver halides suggest that silver(I) fluoride is likely to be more soluble than the other silver halides (which is in fact the case), the hydration enthalpies for the sodium halides almost exactly balance the lattice energies. What then is the driving force which makes these salts soluble, and which indeed must be responsible for the solution process where this is endothermic We have seen on p. 66 the relationship AG = — TAS and... 

READ INPUT DATA FROM MAIN DATA FILE AND PREPARE ARRAYS FOP SOLUTION PROCESS... 

DuponolC DuPontSilverlith Du Pont solution process DuPrene Dupril equation Durability... 

Most cellulose acetate is manufactured by a solution process, ie, the cellulose acetate dissolves as it is produced. The cellulose is acetylated with acetic anhydride acetic acid is the solvent and sulfuric acid the catalyst. The latter can be present at 10—15 wt % based on cellulose (high catalyst process) or at ca 7 wt % (low catalyst process). In the second most common process, the solvent process, methylene chloride replaces the acetic acid as solvent, and perchloric acid is frequentiy the catalyst. There is also a seldom used heterogeneous process that employs an organic solvent as the medium, and the cellulose acetate produced never dissolves. More detailed information on these processes can be found in Reference 28. 

The solution process consists of four steps preparation of cellulose for acetylation, acetylation, hydrolysis, and recovery of cellulose acetate polymer and solvents. A schematic of the total acetate process is shown in Figure 9. 

Hydration. Water adds to the triple bond to yield acetaldehyde via the formation of the unstable enol (see Acetaldehyde). The reaction has been carried out on a commercial scale using a solution process with HgS04/H2S04 catalyst (27,28). The vapor-phase reaction has been reported at... 

Vinyl ethers are prepared in a solution process at 150—200°C with alkaH metal hydroxide catalysts (32—34), although a vapor-phase process has been reported (35). A wide variety of vinyl ethers are produced commercially. Vinyl acetate has been manufactured from acetic acid and acetylene in a vapor-phase process using zinc acetate catalyst (36,37), but ethylene is the currently preferred raw material. Vinyl derivatives of amines, amides, and mercaptans can be made similarly. A/-Vinyl-2-pyrroHdinone is a commercially important monomer prepared by vinylation of 2-pyrroHdinone using a base catalyst. 

Solution Polymerization. Two solution polymerization technologies ate practiced. Processes of the first type utilize heavy solvents those of the second use molten PE as the polymerization medium (57). Polyethylene becomes soluble ia saturated C —hydrocarbons above 120—130°C. Because the viscosity of HDPE solutions rapidly iacrease with molecular weight, solution polymerization is employed primarily for the production of low mol wt resias. Solution process plants were first constmcted for the low pressure manufacture of PE resias ia the late 1950s they were later exteasively modified to make their operatioa economically competitive. 

Most catalysts for solution processes are either completely soluble or pseudo-homogeneous all their catalyst components are introduced into the reactor as Hquids but produce soHd catalysts when combined. The early Du Pont process employed a three-component catalyst consisting of titanium tetrachloride, vanadium oxytrichloride, and triisobutjlalurninum (80,81), whereas Dow used a mixture of titanium tetrachloride and triisobutylalurninum modified with ammonia (86,87). Because processes are intrinsically suitable for the use of soluble catalysts, they were the first to accommodate highly active metallocene catalysts. Other suitable catalyst systems include heterogeneous catalysts (such as chromium-based catalysts) as well as supported and unsupported Ziegler catalysts (88—90). 

As a rule, LLDPE resins do not contain long-chain branches. However, some copolymers produced with metallocene catalysts in solution processes can contain about 0.002 long-chain branches per 100 ethylene units (1). These branches are formed in auto-copolymerisation reactions of ethylene with polymer molecules containing vinyl double bonds on their ends (2). 

Solution Polymerization. Two types of solution polymerization technologies are used for LLDPE synthesis. One process utilizes heavy solvents the other is carried out in mixtures of supercritical ethylene and molten PE as a polymerization medium. Original solution processes were introduced for low pressure manufacture of PE resins in the late 1950s subsequent improvements of these processes gradually made them economically competitive with later, more advanced technologies. 

In the early 1990s, solution processes acquired new importance because of their shorter residence times and abiUty to accommodate metallocene catalysts. Many heterogeneous multicenter Ziegler catalysts produce superior LLDPE resins with a better branching uniformity if the catalyst residence time in a reactor is short. Solution processes usually operate at residence times of around 5—10 min or less and are ideal for this catalyst behavior. Solution processes, both in heavy solvents and in the polymer melt, are inherently suitable to accommodate soluble metallocene catalysts (52). For this reason, these processes were the first to employ metallocene catalysts for LLDPE and VLDPE manufacture. 

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). 

Eastman Chemical has utilized a unique, high temperature solution process for propylene polymerization. Polymerization temperatures are maintained above 150°C to prevent precipitation of the isotactic polypropylene product in the hydrocarbon solvent. At these temperatures, the high rate of polymerization decreases rapidly, requiring low residence times (127). Stereoregularity is also adversely affected by high temperatures. Consequentiy, the... 

Hydrogen sulfide, H2S, is removed by a variety of processes, of which one is a regenerative solution process using aqueous solutions of sodium hydroxide, NaOH, calcium hydroxide, Ca(OH)2, sodium phosphate, Na PO, and sodium carbonate, Na2C02. 

Ionic polymerizations are almost exclusively solution processes. To produce monodisperse polymers or block copolymers, they must be mn batchwise, so that all chains grow for the same length of time under identical conditions. 

Most commercial processes produce polypropylene by a Hquid-phase slurry process. Hexane or heptane are the most commonly used diluents. However, there are a few examples in which Hquid propylene is used as the diluent. The leading companies involved in propylene processes are Amoco Chemicals (Standard OH, Indiana), El Paso (formerly Dart Industries), Exxon Chemical, Hercules, Hoechst, ICl, Mitsubishi Chemical Industries, Mitsubishi Petrochemical, Mitsui Petrochemical, Mitsui Toatsu, Montedison, Phillips Petroleum, SheU, Solvay, and Sumimoto Chemical. Eastman Kodak has developed and commercialized a Hquid-phase solution process. BASE has developed and commercialized a gas-phase process, and Amoco has developed a vapor-phase polymerization process that has been in commercial operation since early 1980. 

Vitreous sihca does not react significantly with water under ambient conditions. The solution process involves the formation of monosilicic acid, Si(OH)4. Solubihty is fairly constant at low pH but increases rapidly when the pH exceeds 9 (84—86). Above a pH of 10.7 sihca dissolves mainly as soluble sihcates. Solubihty also increases with higher temperatures and pressures. At 200—400°C and 1—30 MPa (<10 300 atm), for example, the solubihty, S, of Si02 in g/kg H2O can be expressed as foUows, where d ls the density of the vapor phase and T is the absolute temperature in Kelvin. 

X 10 mol/L in 8 Mpotassium hydroxide at room temperature. In general it is believ ed tliat tlie solution process consists of anodic dissolution of cadmium ions in tlie form of complex hydroxides (see Cadmium compounds). 

Cellulose Acetate. Almost all cellulose acetate, with the exception of fibrous triacetate, is prepared by a solution process employing sulfuric... 

Solution Process. With the exception of fibrous triacetate, practically all cellulose acetate is manufactured by a solution process using sulfuric acid catalyst with acetic anhydride in an acetic acid solvent. An excellent description of this process is given (85). In the process (Fig. 8), cellulose (ca 400 kg) is treated with ca 1200 kg acetic anhydride in 1600 kg acetic acid solvent and 28—40 kg sulfuric acid (7—10% based on cellulose) as catalyst. During the exothermic reaction, the temperature is controlled at 40—45°C to minimize cellulose degradation. After the reaction solution becomes clear and fiber-free and the desired viscosity has been achieved, sufficient aqueous acetic acid (60—70% acid) is added to destroy the excess anhydride and provide 10—15% free water for hydrolysis. At this point, the sulfuric acid catalyst may be partially neutralized with calcium, magnesium, or sodium salts for better control of product molecular weight. 

Various processes can be employed to manufacture urea—formaldehyde products. They are generally categorized into two types, ie, dilute solution processes and concentrated solution processes. Table 3 Hsts select U.S. manufacturers of UF reaction products and their products. 

The first pubHshed information on the halogenation of butyl mbber was provided by B. F. Goodrich Co. (2). Brominating agents such as /V-bromosuccinimide were used the bromination occurred ia a bulk reaction. This technology was commercialized ia 1954, but withdrawn ia 1969 (3). Exxon Chemical researchers pursued the chlorination of butyl mbber ia hexane solution usiag elemental chlorine, and a continuous process was commercialized ia 1961 (4). Currentiy, both chlorination and bromination are carried out ia continuous-solution processes. 

Several patents describe solvent-free bulk-phase halogenation (67—69). Dry soHd butyl mbber is fed into a specially designed extmder reactor and contacted with chlorine or bromine vapor. The by-product HCl or HBr ate vented directly without a separate neutralization step. Halogenated butyl mbbers produced are essentially comparable in composition and properties to commercial products made by the solution process. 

EPM and EPDM mbbers are produced in continuous processes. Most widely used are solution processes, in which the polymer produced is in the dissolved state in a hydrocarbon solvent (eg, hexane). These processes can be grouped into those in which the reactor is completely filled with the Hquid phase, and those in which the reactor contents consist pardy of gas and pardy of a Hquid phase. In the first case the heat of reaction, ca 2500 kJ (598 kcal)/kg EPDM, is removed by means of cooling systems, either external cooling of the reactor wall or deep-cooling of the reactor feed. In the second case the evaporation heat from unreacted monomers also removes most of the heat of reaction. In other processes using Hquid propylene as a dispersing agent, the polymer is present in the reactor as a suspension. In this case the heat of polymerisation is removed mainly by monomer evaporation. 

Using a solution process, the choice of catalyst system is determined, among other things, by the nature of the third monomer and factors such as the width of the mol wt distribution to be realised in the product. A number of articles review the induence of catalyst systems on the stmctural features of the products obtained (3,5—7). The catalyst comprises two main components first, a transition-metal haHde, such as TiCl, VCl, VOCl, etc, of which VOCl is the most widely used second, a metal alkyl component such as (C2H )2A1C1 diethylalurninum chloride, or monoethyl aluminum dichloride, (C2H )AlCl2, or most commonly a mixture of the two, ie, ethyl aluminum sesquichloride, [(C2H )2Al2Cl2]. 

---