Vinyl chlorides, metalation

Mixed Metal Antimony Synergists Worldwide scarcities of antimony have prompted manufacturers to develop synergists that contain less antimony. Other metals have been found to work in concert with antimony to form a synergist that is as effective as antimony alone. Thermoguard CPA from Elf Atochem NA, which contains zinc in addition to antimony, can be used instead of antimony oxide in flexible poly(vinyl chloride) (PVC) as well as some polyolefin appHcations. The Oncor and AZ products which contain siUcon, zinc, and phosphoms from Anzon Inc. can be used in a similar manner. The mixed metal synergists are 10 to 20% less expensive than antimony trioxide. 

Structural Components. In most appHcations stmctural foam parts are used as direct replacements for wood, metals, or soHd plastics and find wide acceptance in appHances, automobUes, furniture, materials-handling equipment, and in constmction. Use in the huil ding and constmction industry account for more than one-half of the total volume of stmctural foam appHcations. High impact polystyrene is the most widely used stmctural foam, foUowed by polypropylene, high density polyethylene, and poly(vinyl chloride). The constmction industry offers the greatest growth potential for ceUular plastics. 

Heat stabilizers protect polymers from the chemical degrading effects of heat or uv irradiation. These additives include a wide variety of chemical substances, ranging from purely organic chemicals to metallic soaps to complex organometaUic compounds. By far the most common polymer requiring the use of heat stabilizers is poly(vinyl chloride) (PVC). However, copolymers of PVC, chlorinated poly(vinyl chloride) (CPVC), poly(vinyhdene chloride) (PVDC), and chlorinated polyethylene (CPE), also benefit from this technology. Without the use of heat stabilizers, PVC could not be the widely used polymer that it is, with worldwide production of nearly 16 million metric tons in 1991 alone (see Vinyl polymers). 

AppHcation of an adhesion-promoting paint before metal spraying improves the coating. Color-coded paints, which indicate compatibiHty with specific plastics, can be appHed at 20 times the rate of grit blasting, typically at 0.025-mm dry film thickness. The main test and control method is cross-hatch adhesion. Among the most common plastics coated with such paints are polycarbonate, poly(phenylene ether), polystyrene, ABS, poly(vinyl chloride), polyethylene, polyester, and polyetherimide. 

Liquid polyalurninum chloride is acidic and corrosive to common metals. Suitable materials for constmction of storage and handling facilities include synthetic mbber-lined steel, corrosion resistant fiber glass reinforced plastics (FRP), ceramics, tetrafluoroethylene polymer (PTFE), poly(vinyhdene fluoride) (PVDF), polyethylene, polypropylene, and poly(vinyl chloride) (PVG). Suitable shipping containers include mbber-lined tank tmcks and rail cars for bulk shipment and plastic-lined or aH-plastic dmms and tote bins for smaller quantities. Except for aluminum chlorohydrates, PAG products are shipped as hazardous substances because of their acidity. 

Polymers. In combination with various metal salts, sorbitol is used as a stabilizer against heat and light in poly(vinyl chloride) (qv) resins and, with a phenohc antioxidant, as a stabilizer in uncured styrene—butadiene mbber (qv) compositions and in polyolefins (see Heat stabilizers Olefin POLYMERS Rubbercompounding). Heat-sealable films are prepared from a dispersion of sorbitol and starch in water (255). Incorporation of sorbitol in coUagen films gready restricts their permeabiUty to carbon dioxide (256). 

Titanium—Vanadium Mixed Metal Alkoxides. Titanium—vanadium mixed metal alkoxides, VO(OTi(OR)2)2, are prepared by reaction of titanates, eg, TYZOR TBT, with vanadium acetate ia a high boiling hydrocarbon solvent. The by-product butyl acetate is distilled off to yield a product useful as a catalyst for polymeri2iag olefins, dienes, styrenics, vinyl chloride, acrylate esters, and epoxides (159,160). 

Substitution at the Carbon—Chlorine Bond. Vinyl chloride is generally considered inert to nucleophilic replacement compared to other alkyl halides. However, the chlorine atom can be exchanged under nucleophilic conditions in the presence of palladium [7440-05-3] Pd, and certain other metal chlorides and salts. Vinyl alcoholates, esters, and ethers can be readily produced from these reactions. 

Use of alcohol as a solvent for carbonylation with reduced Pd catalysts gives vinyl esters. A variety of acrylamides can be made through oxidative addition of carbon monoxide [630-08-0] CO, and various amines to vinyl chloride in the presence of phosphine complexes of Pd or other precious metals as catalyst (14). 

Addition. Chlorine adds to vinyl chloride to form 1,1,2-trichloroethane [79-00-5] (44—46). Chlorination can proceed by either an ionic or a radical path. In the Hquid phase and in the dark, 1,1,2-trichloroethane forms by an ionic path when a transition-metal catalyst such as ferric chloride [7705-08-0], FeCl, is used. The same product forms in radical reactions up to 250°C. Photochernically initiated chlorination also produces... 

Hydrogen haHde addition to vinyl chloride in general yields the 1,1-adduct (50—52). The reactions of HCl and hydrogen iodide [10034-85-2], HI, with vinyl chloride proceed by an ionic mechanism, while the addition of hydrogen bromide [10035-10-6], HBr, involves a chain reaction in which a bromine atom [10097-32-2] is the chain carrier (52). In the absence of a transition-metal catalyst or antioxidants, HBr forms the 1,2-adduct with vinyl chloride (52). HF reacts with vinyl chloride in the presence of stannic chloride [7646-78-8], SnCl, to form 1,1-difluoroethane [75-37-6] (53). 

Condensation of vinyl chloride with formaldehyde and HCl (Prins reaction) yields 3,3-dichloro-l-propanol [83682-72-8] and 2,3-dichloro-l-propanol [616-23-9]. The 1,1-addition of chloroform [67-66-3] as well as the addition of other polyhalogen compounds to vinyl chloride are cataly2ed by transition-metal complexes (58). In the presence of iron pentacarbonyl [13463-40-6] both bromoform [75-25-2] CHBr, and iodoform [75-47-8] CHl, add to vinyl chloride (59,60). Other useful products of vinyl chloride addition reactions include 2,2-di luoro-4-chloro-l,3-dioxolane [162970-83-4] (61), 2-chloro-l-propanol [78-89-7] (62), 2-chloropropionaldehyde [683-50-1] (63), 4-nitrophenyl-p,p-dichloroethyl ketone [31689-13-1] (64), and p,p-dichloroethyl phenyl sulfone [3123-10-2] (65). 

When dry and in contact with metals, vinyl chloride does not decompose below 450°C. However, if water is present, vinyl chloride can corrode iron, steel, and aluminum because of the presence of trace amounts of HCl. This HCl may result from the hydrolysis of the peroxide formed between oxygen and vinyl chloride. 

Process water streams from vinyl chloride manufacture are typically steam-stripped to remove volatile organics, neutralized, and then treated in an activated sludge system to remove any nonvolatile organics. If fluidized-bed oxychlorination is used, the process wastewater may also contain suspended catalyst fines and dissolved metals. The former can easily be removed by sedimentation, and the latter by precipitation. Depending on the specific catalyst formulation and outfall limitations, tertiary treatment may be needed to reduce dissolved metals to acceptable levels. 

Ethylhexanal, the reduced aldol condensation product of //-butyraldehyde, is converted into 2-ethylhexanoic acid [149-57-5] which is converted primarily into salts or metal soaps. These are used as paint driers and heat stabili2ers for poly(vinyl chloride). 

Miscellaneous Reactions. Epoxy compounds yield chlorosubstituted carbonates (45). The reaction of chloroformates with hydrogen peroxide or metal peroxides results in the formation of peroxydicarbonates that are used as free-radical initiators of polymerization of vinyl chloride, ethylene, and other unsaturated monomers (46,47). 

Neodecanoic acid is also used as the carrier for metals in poly(vinyl chloride) heat stabilizers (qv). Metals used in this appHcation include barium, cadmium, and zinc. Tin as the neodecanoate salt has also been claimed as a heat stabilizer for maleic anhydride (97). 

Dichloroethane is produced commercially from hydrogen chloride and vinyl chloride at 20—55°C ia the presence of an aluminum, ferric, or 2iac chloride catalyst (8,9). Selectivity is nearly stoichiometric to 1,1-dichloroethane. Small amounts of 1,1,3-tfichlorobutane may be produced. Unreacted vinyl chloride and HCl exit the top of the reactor, and can be recycled or sent to vent recovery systems. The reactor product contains the Lewis acid catalyst and must be separated before distillation. Spent catalyst may be removed from the reaction mixture by contacting with a hydrocarbon or paraffin oil, which precipitates the metal chloride catalyst iato the oil (10). Other iaert Hquids such as sdoxanes and perfluorohydrocarbons have also been used (11). 

Pyrolysis. Pyrolysis of 1,2-dichloroethane in the temperature range of 340—515°C gives vinyl chloride, hydrogen chloride, and traces of acetylene (1,18) and 2-chlorobutadiene. Reaction rate is accelerated by chlorine (19), bromine, bromotrichloromethane, carbon tetrachloride (20), and other free-radical generators. Catalytic dehydrochlorination of 1,2-dichloroethane on activated alumina (3), metal carbonate, and sulfate salts (5) has been reported, and lasers have been used to initiate the cracking reaction, although not at a low enough temperature to show economic benefits. 

More than half the metal stearates produced in the United States are appHed as lubricants and heat stabili2ers (qv) in plastics, particularly in the processing of poly(vinyl chloride) (PVC) resins. 

At least two catalytic processes have been used to purify halogenated streams. Both utilize fluidized beds of probably noimoble metal catalyst particles. One has been estimated to oxidize >9000 t/yr of chlorinated wastes from a vinyl chloride monomer plant (45). Several companies have commercialized catalysts which are reported to resist deactivation from a wider range of halogens. These newer catalysts may allow the required operating temperatures to be reduced, and stiU convert over 95% of the halocarbon, such as trichlorethylene, from an exhaust stream. Conversions of C-1 chlorocarbons utilizing an Englehardt HDC catalyst are shown in Figure 8. For this system, as the number of chlorine atoms increases, the temperatures required for destmction decreases. 

Other polymers can be more troublesome. Poly(vinyl chloride) requires the incorporation of stabilisers and even so may discolour and give off hydrochloric acid, the latter having a corrosive effect on many metals. At the same time some metals have a catalytic effect on this polymer so that care has to be taken in the construction of barrels, screws and other metal parts liable to come into contact with the polymer. 

In the massive form poly(vinyl chloride) is a colourless rigid material with limited heat stability and with a tendency to adhere to metallic surfaces when heated. For these, and other, reasons it is necessary to compound the polymer with other ingredients to make useful plastics materials. By such means it is possible to produce a wide range of products, including rigid piping and soft elastic cellular materials. 

The polymer may be prepared readily in bulk, emulsion and suspension, the latter technique apparently being preferred on an industrial scale. The monomer must be free from oxygen and metallic impurities. Peroxide such as benzoyl peroxide are used in suspension polymerisations which may be carried out at room temperature or at slightly elevated temperatures. Persulphate initiators and the conventional emulsifying soaps may be used in emulsion polymerisation. The polymerisation rate for vinylidene chloride-vinyl chloride copolymers is markedly less than for either monomer polymerised alone. 

Jones, F.R., Interfacial aspects of glass fibre reinforced plastics. In Jones, F.R. (Ed.), Interfacial Phenomena in Composite Materials. Butterworths, London, 1989, pp. 25-32. Chaudhury, M.K., Gentle, T.M. and Plueddemann, E., Adhesion mechanism of poly(vinyl chloride) to silane primed metal surfaces. J. Adhes. Sci. Technol, 1(1), 29-38 (1987). Gellman, A.J., Naasz, B.M., Schmidt, R.G., Chaudhury, M.K, and Gentle, T.M., Secondary neutral mass spectrometry studies of germanium-silane coupling agent-polymer interphases. J. Adhes. Sci. Technol., 4(7), 597-601 (1990). 

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