Styrene monomer polymerization

The continuous mass process is divided into 4 steps rubber solution in styrene monomer, polymerization, devolatilization and compounding. In 1970 N. Platzer (40) drew up a survey of the state of the art. Polymerization is divided into prepolymerization and main polymerization for both steps reactor designs other than the tower reactors shown in Figure 2 have been proposed. Main polymerization is taken to a conversion of 75 to 85% residual monomer and any solvent are separated under vacuum. The copolymer then passes to granulating equipment, frequently through one or more intermediate extruders in which colorant and other auxiliaries are added. 

Polystyrene is produced by styrene monomer polymerization, which leads to an amorphous, non-flexible polymer having good electrical insulation properties and a density of about 1.04 g/cm3. However, its high brittleness and low softening temperature (<100°C) are important limitations on its industrial application. PS is used in the manufacture of radio and TV parts, toys, electronic components, etc. 

The reaction rate of fumarate polyester polymers with styrene is 20 times that of similar maleate polymers. Commercial phthaHc and isophthaHc resins usually have fumarate levels in excess of 95% and demonstrate full hardness and property development when catalyzed and cured. The addition polymerization reaction between the fumarate polyester polymer and styrene monomer is initiated by free-radical catalysts, commercially usually benzoyl peroxide (BPO) and methyl ethyl ketone peroxide (MEKP), which can be dissociated by heat or redox metal activators into peroxy and hydroperoxy free radicals. 

The free styrene monomer is restrained within the gel and further reaction with fumarate groups is determined by the spacial arrangement the styrene polymerizes in homopolymer blocks as it intercepts fumarate reaction sites. As individual micelles expand and deplete available fumarate sites in the short polymer chains, the remaining styrene forms homopolymer blocks that terminate at the boundaries between overlapping micelles (Fig. 4). 

Styrene [100-42-5] (phenylethene, viaylben2ene, phenylethylene, styrol, cinnamene), CgH5CH=CH2, is the simplest and by far the most important member of a series of aromatic monomers. Also known commercially as styrene monomer (SM), styrene is produced in large quantities for polymerization. It is a versatile monomer extensively used for the manufacture of plastics, including crystalline polystyrene, mbber-modifted impact polystyrene, expandable polystyrene, acrylonitrile—butadiene—styrene copolymer (ABS), styrene—acrylonitrile resins (SAN), styrene—butadiene latex, styrene—butadiene mbber (qv) (SBR), and unsaturated polyester resins (see Acrylonithile polya rs Styrene plastics). 

Table 5. Specifications for Typical Polymerization-Grade Styrene Monomer Product...

OC-Methylstyrene. This compound is not a styrenic monomer in the strict sense. The methyl substitution on the side chain, rather than the aromatic ring, moderates its reactivity in polymerization. It is used as a specialty monomer in ABS resins, coatings, polyester resins, and hot-melt adhesives. As a copolymer in ABS and polystyrene, it increases the heat-distortion resistance of the product. In coatings and resins, it moderates reaction rates and improves clarity. Physical properties of a-methylstyrene [98-83-9] are shown in Table 12. 

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). 

This product is a difunctional initiator and can polymerize styrene monomer ... 

Sequential one styrene block is polymerized, then the mid-block monomer is added and polymerized, then more styrene is added and the second styrene block polymerized. This process is used to produce 100% triblock rubbers, for maximum strength [5]. Termination is commonly with alcohols, which produces a lithium alkoxide salt as the by-product. 

Superheated steam is used to bring the feed to reaction temperature. Reactor effluent is quenched, distilled to remove unreacted feed plus benzene and toluene made during the reaction, and the crude styrene finished by vacuum distillation. Inhibitors are added during the distillation steps to prevent polymerization of the styrene monomer. 

A 3,500-gal reaetor with styrene monomer undergoes adiabatie polymerization after being heated inadvertently to 70°C. The maximum allowable working pressure (MAWP) of the reaetor is 5 bar absolute. Determine the relief vent diameter required. Assume a set pressure of 4.5 bara and a maximum pressure of 5.4 bara. Other data and physieal properties are given as follows [12] ... 

The free radical initiators are more suitable for the monomers having electron-withdrawing substituents directed to the ethylene nucleus. The monomers having electron-supplying groups can be polymerized better with the ionic initiators. The water solubility of the monomer is another important consideration. Highly water-soluble (relatively polar) monomers are not suitable for the emulsion polymerization process since most of the monomer polymerizes within the continuous medium, The detailed emulsion polymerization procedures for various monomers, including styrene [59-64], butadiene [61,63,64], vinyl acetate [62,64], vinyl chloride [62,64,65], alkyl acrylates [61-63,65], alkyl methacrylates [62,64], chloroprene [63], and isoprene [61,63] are available in the literature. 

Figure 16 The variation of the monomer conversion by the polymerization time at different monomer to dispersion medium ratios in the dispersion polymerization of styrene. Monomer/dispersion medium (mL/mL) (a) 5/100, (b) 10/ 100, (c) 20/100. The original SEM photographs were taken with 2600 X, 2(KX) x, and 2600 x magnifications for (a), (b), and (c), respectively, and reduced at a proper ratio to place the figure. (From Ref. 93. Reproduced with the permission of John Wiley Sons, Inc.)...

In another study, uniform composite polymethyl-methacrylate/polystyrene (PMMA/PS) composite particles in the size range of 1-10 fim were prepared by the seeded emulsion polymerization of styrene [121]. The PMMA seed particles were initially prepared by the dispersion polymerization of MMA by using AIBN as the initiator. In this polymerization, poly(7V-vinyl pyrolli-done) and methyl tricaprylyl ammonium chloride were used as the stabilizer and the costabilizer, respectively, in the methanol medium. Seed particles were swollen with styrene monomer in a medium comprised of seed particles, styrene, water, poly(7V-vinyl pyrollidone), Polywet KX-3 and aeorosol MA emulsifiers, sodium bicarbonate, hydroquinone inhibitor, and azobis(2-methylbu-... 

The formation of the polyalloy results in improvement in the performance of the blends. This system is similar to the production of high-impact polystyrene (HIPS) where a rubber is dissolved in styrene monomer and then polymerized in the usual way. Even though the impact strength of the compatibilized PS-PE blend was higher than that of PS, it was much less than that of HIPS. In another study. Van Ballegooie and [55] have confirmed... 

Polyaddition reactions based on isocyanate-terminated poly(ethylene glycol)s and subsequent block copolymerization with styrene monomer were utilized for the impregnation of wood [54]. Hazer [55] prepared block copolymers containing poly(ethylene adipate) and po-ly(peroxy carbamate) by an addition of the respective isocyanate-terminated prepolymers to polyazoesters. By both bulk and solution polymerization and subsequent thermal polymerization in the presence of a vinyl monomer, multiblock copolymers could be formed. 

When an unsymmetrically substituted vinyl monomer such as propylene or styrene is polymerized, the radical addition steps can take place at either end of the double bond to yield either a primary radical intermediate (RCH2-) or a secondary radical (R2CH-). Just as in electrophilic addition reactions, however, we find that only the more highly substituted, secondary radical is formed. 

Various methylene derivatives of spiroorthocarbonates and spiroorthocstcrs have been reported to give double ring-opening polymerization e.g. Scheme 4.36). Like the parent monocyclic systems, these monomers can be sluggish to polymerize and reactivity ratios are such that they do not undergo ready copolymerization with acrylic and styrenic monomers. Copolymerizations with VAc have been reported.170 These monomers, like other acetals, show marked acid sensitivity. 

Paraplex Resin-Bonded Explosive. Usually consists of Paraplex P-43/RDX/Al/Styrene monomer/ Lupersol DDM (as a polymerization catalyst) in the following percentages, viz 6.0/65.0/ 20.0/9.0/0.5. Density 1.65g/cc. The material is mixed and polymerized using the usual procedure for polyester resins and Plastic Bonded Expls (see in this Vol)... 

Uses. There are about forty to fifty organic peroxides commercially available in more than seventy formulations designed for specific applications which include (1) initiators for vinyl monomer polymerizations, and copolymerizations of monomers such as vinyl chloride, ethylene, styrene, vinyl acetate, acrylics, fluoroolefms and buta-dienestyrene (2) curing agents for thermoset polyesters, styrenated alkyds and oils, silicone rubbers and poly allyl diglycol carbonates ... 

A well-known high conversion reactor is the so-called polymerization press, a modified plate-and-frame filter press where polystyrene is polymerized in frames alternating between cooling platens through which water (or steam) can be circulated. Other versions of the high conversion reactor have been utilized, e.g., the early "can process of Dow, where styrene monomer was placed in sealed cans in water baths and the metal stripped off at the end of the polymerization 2). 

Reaction Mechanism. The reaction mechanism of the anionic-solution polymerization of styrene monomer using n-butyllithium initiator has been the subject of considerable experimental and theoretical investigation (1-8). The polymerization process occurs as the alkyllithium attacks monomeric styrene to initiate active species, which, in turn, grow by a stepwise propagation reaction. This polymerization reaction is characterized by the production of straight chain active polymer molecules ("living" polymer) without termination, branching, or transfer reactions. 

Most addition polymerizations involve vinyl or diene monomers. The opening of a double bond can be catalyzed in several ways. Free-radical polymerization is the most common method for styrenic monomers, whereas coordination metal... 

The verification of EPM on the well characterized styrene and styrene-MMA polymerizations has allowed us to use the same model structure to obtain fundamental insights into emulsion polymerizations involving other monomers of significant importance to Du Pont. 

Transfer constants for polystyrene chain radicals at 60° and 100°C, obtained from the slopes of these plots and others like them, are given in the second and third columns of Table XIII. Almost any solvent is susceptible to attack by the propagating free radical. Even cyclohexane and benzene enter into chain transfer, although to a comparatively small extent only. The specific reaction rate at 100°C for transfer with either of these solvents is less than two ten-thousandths of the rate for the addition of the chain radical to styrene monomer. A fifteenfold dilution with benzene was required to halve the molecular weight, i.e., to double l/xn from its value (l/ rjo for pure styrene (see Fig. 16). Other hydrocarbons are more effective in lowering the degree of polymerization through chain transfer. 

If one of the monomers is very much more reactive than the other, the two monomers tend to polymerize consecutively the first polymer formed will consist predominantly of the more reactive monomer, and the other monomer polymerizes only after nearly all of the former has been consumed. Styrene (l)-vinyl acetate (2) is such a system, r being greater than unity while r is very small (Table XIX) rir2 is less than unity. No curve corresponding to this case is included in Fig. 25. 

For the remaining three systems, styrene-vinyl acetate, vinyl acetate-vinyl chloride, and methyl acrylate-vinyl chloride, one reactivity ratio is greater than unity and the other is less than unity. They are therefore nonazeotropic. Furthermore, since both ri and 1/7 2 are either greater than or less than unity, both radicals prefer the same monomer. In other words, the same monomer—styrene, vinyl chloride, and methyl acrylate in the three systems, respectively—is more reactive than the other with respect to either radical. This preference is extreme in the styrene-vinyl acetate system where styrene is about fifty times as reactive as vinyl acetate toward the styrene radical the vinyl acetate radical prefers to add the styrene monomer by a factor of about one hundred as compared with addition of vinyl acetate. Hence polymerization of a mixture of similar amounts of styrene and vinyl acetate yields an initial product which is almost pure polystyrene. Only after most of the styrene has polymerized is a copolymer formed... 

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