Solvent solution polymerization

Solution polymerization is bulk polymerization in which excess monomer serves as the solvent. Solution polymerization, used at approximately 13 plants, is a newer, less conventional process than emulsion polymerization for the commercial production of crumb mbber. Polymerization generally proceeds by ionic mechanisms. This system permits the use of stereospecific catalysts of the Ziegler-Natta or alkyl lithium types which make it possible to polymerize monomers into a cis structure characteristic that is very similar to that of natural rubber. This cis structure yields a rubbery product, as opposed to a trans stmcture which produces a rigid product similar to plastics. 

Even though monomers are generally quite reactive (polymerizable), they usually require the addition of catalysts, initiators, pH control, heat, and/or vacuum to speed and control the polymerization reaction that will result in optimizing the manufacturing process and final product.74 When pure monomers can be converted directly to pure polymers, it is called the process of bulk polymerization, but often it is more convenient to run the polymerization reaction in an organic solvent (solution polymerization), in a water emulsion (emulsion polymerization), or as organic droplets dispersed in water (suspension polymerization). Often choose of catalyst systems exert precise control over the structure of the polymers they form. They are referred to as stereospecific systems. 

In a homogeneouB phase, in which the monomer is a gas, a liquid, or a solid (bulk polymerization) or in which the monomer is completely dissolved in a solvent (solution polymerization). 

In a suitable solvent, solution polymerization involving the delayed addition of the monomer may be carried out. In this procedure, all of the solvent and 10-25% of the monomer are heated to reflux in the presence of an initiator. As the polymerization proceeds, additional monomer is gradually added. To complete the polymerization, the reaction solution is heated for a prolonged period after the monomer addition has been completed. Even so, the residual monomer content may be as high as 2% [95]. 

In mass polymerization bulk monomer is converted to polymers. In solution polymerization the reaction is completed in the presence of a solvent. In suspension, dispersed mass, pearl or granular polymerization the monomer, containing dissolved initiator, is polymerized while dispersed in the form of fine droplets in a second non-reactive liquid (usually water). In emulsion polymerization an aqueous emulsion of the monomer in the presence of a water-soluble initiator Is converted to a polymer latex (colloidal dispersion of polymer in water). 

In addition to an array of experimental methods, we also consider a more diverse assortment of polymeric systems than has been true in other chapters. Besides synthetic polymer solutions, we also consider aqueous protein solutions. The former polymers are well represented by the random coil model the latter are approximated by rigid ellipsoids or spheres. For random coils changes in the goodness of the solvent affects coil dimensions. For aqueous proteins the solvent-solute interaction results in various degrees of hydration, which also changes the size of the molecules. Hence the methods we discuss are all potential sources of information about these interactions between polymers and their solvent environments. 

Dimethylformamide [68-12-2] (DME) and dimethyl sulfoxide [67-68-5] (DMSO) are the most commonly used commercial organic solvents, although polymerizations ia y-butyrolactoae, ethyleae carboaate, and dimethyl acetamide [127-19-5] (DMAC) are reported ia the hterature. Examples of suitable inorganic salts are aqueous solutioas of ziac chloride and aqueous sodium thiocyanate solutions. The homogeneous solution polymerization of acrylonitrile foUows the conventional kinetic scheme developed for vinyl monomers (12) (see Polymers). 

Chain transfer is an important consideration in solution polymerizations. Chain transfer to solvent may reduce the rate of polymerization as well as the molecular weight of the polymer. Other chain-transfer reactions may iatroduce dye sites, branching, chromophoric groups, and stmctural defects which reduce thermal stabiUty. Many of the solvents used for acrylonitrile polymerization are very active in chain transfer. DMAC and DME have chain-transfer constants of 4.95-5.1 x lO " and 2.7-2.8 x lO " respectively, very high when compared to a value of only 0.05 x lO " for acrylonitrile itself DMSO (0.1-0.8 X lO " ) and aqueous zinc chloride (0.006 x lO " ), in contrast, have relatively low transfer constants hence, the relative desirabiUty of these two solvents over the former. DME, however, is used by several acryhc fiber producers as a solvent for solution polymerization. 

Solution polymerization of VDE in fluorinated and fluorochlorinated hydrocarbons such as CEC-113 and initiated with organic peroxides (99), especially bis(perfluoropropionyl) peroxide (100), has been claimed. Radiation-induced polymerization of VDE has also been investigated (101,102). Alkylboron compounds activated by oxygen initiate VDE polymerization in water or organic solvents (103,104). Microwave-stimulated, low pressure plasma polymerization of VDE gives polymer film that is <10 pm thick (105). Highly regular PVDE polymer with minimized defect stmcture was synthesized and claimed (106). Perdeuterated PVDE has also been prepared and described (107). 

Suspension- and emulsion-polymerized PVDF exhibit dissimilar behavior in solutions. The suspension resin type is readily soluble in many solvents even in good solvents, solutions of the emulsion resin type contain fractions of microgel, which contain more head-to-head chain defects than the soluble fraction of the resin (116). Concentrated solutions (15 wt %) and melt rheology of various PVDF types also display different behavior (132). The Mark-Houwink relation (rj = KM°-) for PVDF in A/-methylpyrrohdinone (NMP) containing 0.1 molar LiBr at 85°C, for the suspension (115) and emulsion... 

Other than fuel, the largest volume appHcation for hexane is in extraction of oil from seeds, eg, soybeans, cottonseed, safflower seed, peanuts, rapeseed, etc. Hexane has been found ideal for these appHcations because of its high solvency for oil, low boiling point, and low cost. Its narrow boiling range minimises losses, and its low benzene content minimises toxicity. These same properties also make hexane a desirable solvent and reaction medium in the manufacture of polyolefins, synthetic mbbers, and some pharmaceuticals. The solvent serves as catalyst carrier and, in some systems, assists in molecular weight regulation by precipitation of the polymer as it reaches a certain molecular size. However, most solution polymerization processes are fairly old it is likely that those processes will be replaced by more efficient nonsolvent processes in time. 

Interfdci l Composite Membra.nes, A method of making asymmetric membranes involving interfacial polymerization was developed in the 1960s. This technique was used to produce reverse osmosis membranes with dramatically improved salt rejections and water fluxes compared to those prepared by the Loeb-Sourirajan process (28). In the interfacial polymerization method, an aqueous solution of a reactive prepolymer, such as polyamine, is first deposited in the pores of a microporous support membrane, typically a polysulfone ultrafUtration membrane. The amine-loaded support is then immersed in a water-immiscible solvent solution containing a reactant, for example, a diacid chloride in hexane. The amine and acid chloride then react at the interface of the two solutions to form a densely cross-linked, extremely thin membrane layer. This preparation method is shown schematically in Figure 15. The first membrane made was based on polyethylenimine cross-linked with toluene-2,4-diisocyanate (28). The process was later refined at FilmTec Corporation (29,30) and at UOP (31) in the United States, and at Nitto (32) in Japan. 

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. 

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. 

Solution Polymerization. In this process an inert solvent is added to the reaction mass. The solvent adds its heat capacity and reduces the viscosity, faciUtating convective heat transfer. The solvent can also be refluxed to remove heat. On the other hand, the solvent wastes reactor space and reduces both rate and molecular weight as compared to bulk polymerisation. Additional technology is needed to separate the polymer product and to recover and store the solvent. Both batch and continuous processes are used. 

Solution polymerization can use various solvents, primarily aUphatic and aromatic hydrocarbons. The choice of solvent is usually dictated by cost, avaHabihty, solvency, toxicity, flammabiUty, and polymer stmcture. SSBR polymerization depends on recovery and reuse of the solvent for economical operation as well as operation under the air-quaUty perrnitting of the local, state, and federal mandates involved. 

Anionic polymerization offers fast polymerization rates on account of the long life-time of polystyryl carbanions. Early studies have focused on this attribute, most of which were conducted at short reactor residence times (< 1 h), at relatively low temperatures (10—50°C), and in low chain-transfer solvents (typically benzene) to ensure that premature termination did not take place. Also, relatively low degrees of polymerization (DP) were typically studied. Continuous commercial free-radical solution polymerization processes to make PS, on the other hand, operate at relatively high temperatures (>100° C), at long residence times (>1.5 h), utilize a chain-transfer solvent (ethylbenzene), and produce polymer in the range of 1000—1500 DP. 

Solution Polymerization. Solution polymerization of vinyl acetate is carried out mainly as an intermediate step to the manufacture of poly(vinyl alcohol). A small amount of solution-polymerized vinyl acetate is prepared for the merchant market. When solution polymerization is carried out, the solvent acts as a chain-transfer agent, and depending on its transfer constant, has an effect on the molecular weight of the product. The rate of polymerization is also affected by the solvent but not in the same way as the degree of polymerization. The reactivity of the solvent-derived radical plays an important part. Chain-transfer constants for solvents in vinyl acetate polymerizations have been tabulated (13). Continuous solution polymers of poly(vinyl acetate) in tubular reactors have been prepared at high yield and throughput (73,74). 

Solution Polymerization. In solution polymerization, a solvent for the monomer is often used to obtain very uniform copolymers. Polymerization rates ate normally slower than those for suspension or emulsion PVC. Eor example, vinyl chloride, vinyl acetate, and sometimes maleic acid are polymerized in a solvent where the resulting polymer is insoluble in the solvent. This makes a uniform copolymer, free of suspending agents, that is used in solution coatings (99). 

Solution Polymerization. This method is not commercially important, although it is convenient and practical, because it provides viscous cements that are difficult to handle. Also, the choice of the solvent is a key parameter due to the high solvent chain-transfer constants for acrylates. 

AGE-Gontaining Elastomers. The manufacturing process for ECH—AGE, ECH—EO—AGE, ECH—PO—AGE, and PO—AGE is similar to that described for the ECH and ECH—EO elastomers. Solution polymerization is carried out in aromatic solvents. Slurry systems have been reported for PO—AGE (39,40). When monomer reactivity ratios are compared, AGE (and PO) are approximately 1.5 times more reactive than ECH. Since ECH is slightly less reactive than PO and AGE and considerably less reactive than EO, background monomer concentration must be controlled in ECH—AGE, ECH—EO—AGE, and ECH—PO—AGE synthesis in order to obtain a uniform product of the desired monomer composition. This is not necessary for the PO—AGE elastomer, as a copolymer of the same composition as the monomer charge is produced. AGE content of all these polymers is fairly low, less than 10%. Methods of molecular weight control, antioxidant addition, and product work-up are similar to those used for the ECH polymers described. 

Alkali Metal Catalysts. The polymerization of isoprene with sodium metal was reported in 1911 (49,50). In hydrocarbon solvent or bulk, the polymerization of isoprene with alkaU metals occurs heterogeneously, whereas in highly polar solvents the polymerization is homogeneous (51—53). Of the alkah metals, only lithium in bulk or hydrocarbon solvent gives over 90% cis-1,4 microstmcture. Sodium or potassium metals in / -heptane give no cis-1,4 microstmcture, and 48—58 mol % /ram-1,4, 35—42% 3,4, and 7—10% 1,2 microstmcture (46). Alkali metals in benzene or tetrahydrofuran with crown ethers form solutions that readily polymerize isoprene however, the 1,4 content of the polyisoprene is low (54). For example, the polyisoprene formed with sodium metal and dicyclohexyl-18-crown-6 (crown ether) in benzene at 10°C contains 32% 1,4-, 44% 3,4-, and 24% 1,2-isoprene units (54). 

Solution Polymerization These processes may retain the polymer in solution or precipitate it. Polyethylene is made in a tubular flow reactor at supercritical conditions so the polymer stays in solution. In the Phillips process, however, after about 22 percent conversion when the desirable properties have been attained, the polymer is recovered and the monomer is flashed off and recyled (Fig. 23-23 ). In another process, a solution of ethylene in a saturated hydrocarbon is passed over a chromia-alumina catalyst, then the solvent is separated and recyled. Another example of precipitation polymerization is the copolymerization of styrene and acrylonitrile in methanol. Also, an aqueous solution of acrylonitrile makes a precipitate of polyacrylonitrile on heating to 80°C (176°F). 

The chemical structure of SBR is given in Fig. 4. Because butadiene has two carbon-carbon double bonds, 1,2 and 1,4 addition reactions can be produced. The 1,2 addition provides a pendant vinyl group on the copolymer chain, leading to an increase in Tg. The 1,4 addition may occur in cis or trans. In free radical emulsion polymerization, the cis to trans ratio can be varied by changing the temperature (at low temperature, the trans form is favoured), and about 20% of the vinyl pendant group remains in both isomers. In solution polymerization the pendant vinyl group can be varied from 10 to 90% by choosing the adequate solvent and catalyst system. 

Chemical Reactivity - Reactivity with Water No reaction Reactivity with Common Materials Corrosive, particularly when diluted. Attacks most common metals, including most stainless steels. Excellent solvent for many synthetic resins or rubber Stability During Transport Stable Neutralizing Agents for Acids and Caustics Dilute with water, rinse with sodium bicarbonate solution Polymerization Not pertinent Inhibitor of Polymerization Not pertinent. 

The principal production methods for acrylamide polymers are polymerization in aqueous solutions, mixed solvent solutions, and various dispersed phases. 

In solution polymerization, an organic solvent dissolves the monomer. Solvents should have low chain transfer activity to minimize chain transfer reactions that produce low-molecular-weight polymers. The presence of a solvent makes heat and viscosity control easier than in bulk polymerization. Removal of the solvent may not be necessary in certain applications such as coatings and adhesives. 

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