Dynamic Modelling of Emulsion Polymerization for the Continuous Production of Nitrile Rubber

Dynamic Modelling of Emulsion Polymerization for the Continuous Production of Nitrile Rubber
Author: Ian David Washington
Publisher:
Total Pages: 194
Release: 2008
Genre:
ISBN:

Commodity and specialty-grade rubbers, such as styrene-butadiene (SBR) or nitrile-butadiene (NBR), are industrially produced in large trains of continuous reactors using an emulsion polymerization process. Both SBR and NBR systems are largely unstudied. Furthermore, the studies that have been published on NBR have been typically limited to issues concerning the characteristics of the product behaviour (i.e. oil/fuel resistance, tensile strength, hardness, compression set). In this work a detailed mathematical model has been developed in order to simulate the industrial production of NBR via emulsion copolymerization of acrylonitrile (AN) and butadiene (Bd) in batch, continuous and trains of continuous reactors. Model predictions include monomer conversion, polymerization rate, copolymer composition, number- and weight-average molecular weights, tri- and tetra-functional branching frequencies, and the number and average size of polymer latex particles. NBR is typically produced at low temperatures (5 to 10 degrees C) using a redox initiation system to generate free radicals. The system is typically composed of three phases, water, polymer particles, and monomer. Surfactants and electrolytes are used to stabilize the particle and monomer phases as polymerization proceeds. Of particular industrial importance, in today's world of tailor-made products, is detailed control over the polymerization reaction. Such control requires a deep understanding of the influence of various reactant feed rates and reactor operating conditions on the process response. In particular, policies to minimize copolymer composition drift and to control molecular weight, polydispersity and chain branching at desirable levels. The model is cast in a dynamic form using ordinary differential equations to describe the change of each species, the average number of particles, total average polymer volume, and the first three leading moments of the molecular weight distribution. With a multiphase system it is necessary to determine the concentration of each component in each phase. For this, a constant partition coefficient approach was adopted, as opposed to a purely thermodynamic approach. Particle generation was modelled considering both micellar and homogeneous mechanisms. Model parameters were obtained from the open literature or arrived at after sensitivity analysis. Simulations starting the reactors full of water, feeding all ingredients to the first reactor and using an average residence time of 60 minutes revealed considerable copolymer drift starting in the forth reactor (33% conversion), and heightened molecular weights and chain branching once the monomer phase disappeared (50% conversion). Further simulations revealed that both copolymer drift and the growth of molecular weight and branching could be controlled through additional feed streams of AN and chain transfer agent to downstream reactors. Furthermore, polymer productivity could be increased by appropriately splitting the total monomer feed between the first couple of reactors in the train.

Emulsion Polymerization and Its Applications in Industry

Emulsion Polymerization and Its Applications in Industry
Author: V. I. Eliseeva
Publisher: Springer Science & Business Media
Total Pages: 231
Release: 2012-12-06
Genre: Technology & Engineering
ISBN: 1468416413

There is a large body of Soviet work on emulsion polymerization, spanning a period of over three decades, that has been published primarily in the Russian language. Most of this has remained untranslated into English and hence un available to most other scientists. The value of this book lies primarily in the fact that it brings together the most important of these Soviet contributions, along with comment and analysis by the authors, who may be considered among the foremost authorities in this field in the Soviet Union. But the hundreds of literature citations go far beyond the borders of the Soviet Union and serve as an excellent bibliography of the world literature on emulsion polymerization up to the time this book was written. The book covers both fundamental and applied aspects. In the former are included discussions of particle formation mechanisms, a comprehensive theory of emulsion polymerization, copolymerization of polar monomers, and particle morphology and its implications with regard to derived film properties. Among the applied aspects are discussions of continuous emulsion polymerization, both tubular reactors and continuous stirred tank cascades, and various aspects con cerning the manufacture of some of the most important monomers, such as styrene, butadiene, vinyl acetate, methyl methacrylate, acrylonitrile, and chloroprene. This book will be an indispensable reference source for scientists who are entering the field as well as those who are experienced and who have wanted a ready access to this large body of literature.

Chemistry and Technology of Emulsion Polymerisation

Chemistry and Technology of Emulsion Polymerisation
Author: A. M. van Herk
Publisher: John Wiley & Sons
Total Pages: 332
Release: 2013-05-13
Genre: Technology & Engineering
ISBN: 1118638360

Chemistry and Technology of Emulsion Polymerisation 2e provides a practical and intuitive explanation of emulsion polymerization, in combination with both conventional and controlled radical polymerization. For those working in industry, coupling theory with everyday practice can be difficult. By carefully explaining the principles of the reaction, based on well-designed experimental investigation, the book explains how the principles relate to practical application. The second edition of this book includes a new chapter on morphology of latex particles, a rapidly progressing area where modelling the thermodynamic and kinetic aspects of phase separation and morphology has developed into a mature and powerful tool to predict and control morphology of latex particles. Another area that is rapidly progressing is the application of controlled radical polymerisation in emulsion polymerization. Controlled radical polymerisation is used in aiding encapsulation of inorganic particles like pigment particles and clay platelets. These latest developments are included in the second edition.

Emulsion Polymerization and Emulsion Polymers

Emulsion Polymerization and Emulsion Polymers
Author: Peter A. Lovell
Publisher: John Wiley & Sons
Total Pages: 858
Release: 1997-04-03
Genre: Science
ISBN:

Emulsion Polymerization and Emulsion Polymers Edited by Peter A. Lovell Manchester Materials Science Centre, UMIST, Manchester, UK and Mohamed S. El-Aasser Emulsion Polymers Institute and Department of Chemical Engineering, Lehigh University, Bethlehem, PA, USA Emulsion polymerization is a technologically and commercially important reaction used to produce synthetic polymers and latexes for a wide range of applications. It is the basis of a massive global industry that is expanding due to the versatility of the reaction and the greater realization of the ability to control properties of the polymer latexes produced. Emulsion Polymerization and Emulsion Polymers provides an up-to-date treatment of both academic and industrial aspects of the subject in a single self-contained volume. Established knowledge is integrated with latest developments and introductory chapters to give a state-of-the-art summary which is also suitable as a broad based introduction to the field. The individual chapters have been written by specialists from academia and industry and are presented in a way which ensures that the book will be of equal value to experienced researchers and students.

Modeling, Simulation, Dynamic Optimization and Control of a Semibatch Emulsion Polymerization Process

Modeling, Simulation, Dynamic Optimization and Control of a Semibatch Emulsion Polymerization Process
Author: Iván-Dario Gil
Publisher:
Total Pages: 0
Release: 2014
Genre:
ISBN:

In this work, modeling, simulation, dynamic optimization and nonlinear control of an industrial emulsion polymerization process to produce poly-vinyl acetate (PVAc) are proposed. The reaction is modeled as a two-phase system composed of an aqueous phase and a particle phase. A detailed model is used to calculate the weight average molecular weight, the number average molecular weight and the dispersity. The moments of the growing and dead chains are used to represent the state of the polymer and to calculate the molecular weight distribution (MWD). The case study corresponds to an industrial reactor operated at a chemical company in Bogotá. An industrial scale reactor (11 m3 of capacity) is simulated where a semi-batch emulsion polymerization reaction of vinyl acetate is performed. Dynamic optimization problem is solved directly using a Nonlinear Programming solver. Integration of differential equations is made using Runge-Kutta method. Three different optimization problems are solved from the more simplistic (only one control variable: reactor temperature) to the more complex (three control variables : reactor temperature, initiator flow rate and monomer flow rate) in order to minimize the reaction time. A reduction of 25% of the batch time is achieved with respect to the normal operating conditions applied at the company. The results show that is possible to minimize the reaction time while some polymer desired qualities (conversion, molecular weight and solids content) satisfy the defined constraints. A nonlinear geometric control technique by using input/output linearization is adapted to the reactor temperature control. An extended Kalman filter (EKF) is implemented to estimate unmeasured states and it is tested in different cases including a robustness study where model errors are introduced to verify its good performance. After verification of controller performance, some process changes were proposed in order to improve process productivity and polymer quality. Finally, the optimal temperature profile and optimal feed policies of the monomer and initiator, obtained in a dynamic optimization step, are used to provide the optimal set points for the nonlinear control. The results show that the nonlinear controller designed here is appropriate to follow the optimal temperature trajectories calculated previously.

Hybrid Latex Particles

Hybrid Latex Particles
Author: Alex M. van Herk
Publisher: Springer
Total Pages: 296
Release: 2010-10-15
Genre: Technology & Engineering
ISBN: 3642160603

Historical Overview of (Mini)emulsion Polymerizations and Preparation of Hybrid Latex Particles, by A.M. van Herk; * Physical Methods for the Preparation of Hybrid Nanocomposite Polymer Latex Particles, by R. F.A. Teixeira and S. A.F. Bon; * Organic/Inorganic Composite Latexes: The Marriage of Emulsion Polymerization and Inorganic Chemistry, by Elodie Bourgeat-Lami and Muriel Lansalot; * Preparation of Hybrid Latex Particles and Core–Shell Particles Through the Use of Controlled Radical Polymerization Techniques in Aqueous Media, by Bernadette Charleux, Franck D’Agosto, and Guillaume Delaittre; * Miniemulsion Polymerization as a Means to Encapsulate Organic and Inorganic Materials, by Clemens K.Weiss and Katharina Landfester; * Organic–Inorganic Hybrid Magnetic Latex, by Md Mahbubor Rahman and Abdelhamid Elaissari

Principles and Applications of Emulsion Polymerization

Principles and Applications of Emulsion Polymerization
Author: Chorng-Shyan Chern
Publisher: John Wiley & Sons
Total Pages: 268
Release: 2008-10-06
Genre: Science
ISBN: 0470377933

Up-to-date coverage of methods of emulsion polymerization This book provides a comprehensive reference on emulsion polymerization methods,focusing on the fundamental mechanisms and kinetics of each process, as well as howthey can be applied to the manufacture of environmentally friendly polymeric materials. Topics covered include: Conventional emulsion polymerization Miniemulsion polymerization Microemulsion polymerization Industrial emulsion polymerization processes (primarily the semibatch and continuous reactions systems) The role of various colloidal phenomena in emulsion polymerization Important end-use properties of emulsion polymer (latex) products Information on industrial applications in paints, coatings, adhesives, paper and board, and more This is a hands-on reference for graduate students and professionals in polymerchemistry, chemical engineering, and materials science who are involved in researchon coatings, adhesives, rubber, latex, paints, finishes, and other materials that can becreated using various methods of emulsion polymerization.