Model‐Assisted Optimization of RAFT Polymerization in Micro‐Scale Reactors—A Fast Screening Approach

Development and Experimental Validation of a Dispersity Model for In Silico RAFT Polymerization

The exploitation of computational techniques to predict the outcome of chemical reactions is becoming commonplace, enabling a reduction in the number of physical experiments required to optimize a reaction. Here, we adapt and combine models for polymerization kinetics and molar mass dispersity as a function of conversion for reversible addition fragmentation chain transfer (RAFT) solution polymerization, including the introduction of a novel expression accounting for termination. A flow reactor operating under isothermal conditions was used to experimentally validate the models for the RAFT polymerization of dimethyl acrylamide with an additional term to accommodate the effect of residence time distribution. Further validation is conducted in a batch reactor, where a previously recorded in situ temperature monitoring provides the ability to model the system under more representative batch conditions, accounting for slow heat transfer and the observed exotherm. The model also shows agreement with several literature examples of the RAFT polymerization of acrylamide and acrylate monomers in batch reactors. In principle, the model not only provides a tool for polymer chemists to estimate ideal conditions for a polymerization, but it can also automatically define the initial parameter space for exploration by computationally controlled reactor platforms provided a reliable estimation of rate constants is available. The model is compiled into an easily accessible application to enable simulation of RAFT polymerization of several monomers.

Determination of Reactivity Ratios from Binary Copolymerization Using the k-Nearest Neighbor Non-Parametric Regression

This paper proposes a new method for calculating the monomer reactivity ratios for binary copolymerization based on the terminal model. The original optimization method involves a numerical integration algorithm and an optimization algorithm based on k-nearest neighbour non-parametric regression. The calculation method has been tested on simulated and experimental data sets, at low (<10%), medium (10–35%) and high conversions (>40%), yielding reactivity ratios in a good agreement with the usual methods such as intersection, Fineman–Ross, reverse Fineman–Ross, Kelen–Tüdös, extended Kelen–Tüdös and the error in variable method. The experimental data sets used in this comparative analysis are copolymerization of 2-(N-phthalimido) ethyl acrylate with 1-vinyl-2-pyrolidone for low conversion, copolymerization of isoprene with glycidyl methacrylate for medium conversion and copolymerization of N-isopropylacrylamide with N,N-dimethylacrylamide for high conversion. Also, the possibility to estimate experimental errors from a single experimental data set formed by n experimental data is shown.

Evaluation of Thermal Hazard Properties of Low Temperature Active Azo Compound under Process Conditions for Polymer Resin in Construction Industries

The application of polymerization initiators in a process can improve reaction efficiency and reduce energy loss. Azo compounds (azos) provide the required energy and promote polymerization for construction due to the heat release in the decomposition reaction. However, the heat release also brings related thermal hazards due to the lack of proper control. To reduce and avoid possible future hazards, the new azo initiators, 2,2′-Azobis(2-methylpropionamide)dihydrochloride (AIBA) is selected to explore the related thermal properties that are less studied by past literature. For the chemical process, its chemical reaction mechanism is extremely essential. In addition to being an influential foundation for process control, it is also used as a calculation basis for subsequent thermal hazard parameters, which is suitable for evaluating the degree of thermal hazard and emergency response. The assessment program includes kinetic model simulations and consecutive calculation on thermal safety parameters, such as TMRad and TCL for process operations. This study combines the thermogravimetric data with the nonlinear kinetics fitting on thermogram. The fitting results are derived back to the analysis formula which corresponds to the reaction mode to obtain the elementary reaction parameters and establish the kinetics process. The runaway mode and consequent thermal hazard parameters can also be obtained.

Experimental Design in Polymer Chemistry-A Guide towards True Optimization of a RAFT Polymerization Using Design of Experiments (DoE)

Despite the great potential of design of experiments (DoE) for efficiency and plannability in academic research, it remains a method predominantly used in industrial processes. From our perspective though, DoE additionally provides greater information gain than conventional experimentation approaches, even for more complex systems such as chemical reactions. Hence, this work presents a comprehensive DoE investigation on thermally initiated reversible addition–fragmentation chain transfer (RAFT) polymerization of methacrylamide (MAAm). To facilitate the adaptation of DoE for virtually every other polymerization, this work provides a step-by-step application guide emphasizing the biggest challenges along the way. Optimization of the RAFT system was achieved via response surface methodology utilizing a face-centered central composite design (FC-CCD). Highly accurate prediction models for the responses of monomer conversion, theoretical and apparent number averaged molecular weights, and dispersity are presented. The obtained equations not only facilitate thorough understanding of the observed system but also allow selection of synthetic targets for each individual response by prediction of the respective optimal factor settings. This work successfully demonstrates the great capability of DoE in academic research and aims to encourage fellow scientists to incorporate the technique into their repertoire of experimental strategies.

Zero-Discharge Process for Recycling of Tetrahydrofuran–Water Mixtures

The sustainable design of separation and polymer synthesis processes is of great importance. Therefore, an energy-efficient process for the purification of tetrahydrofuran (THF)–water (H2O) solvent mixtures from an upstream polymer synthesis process in pilot scale was developed with the aim to obtain high purity separation products. The advantages and limitations of a hybrid process in the pilot scale were studied utilizing an Aspen Plus Dynamics® simulation at different pressures to prove the feasibility and energy efficiency. For the rough separation of the two components, distillation was chosen as the first process step. In this way, a separation of a water stream of sufficient quality for further precipitations after polymer synthesis could be achieved. In order to overcome the limitations of the distillation process posed by the azeotropic point of the mixture, a vapor permeation is used, which takes advantage of the heat of evaporation already used in the distillation column. For the purpose of achieving the required low water contents, an adsorption column is installed downstream for final THF purification. This leads to a novel hybrid separation process that is energy efficient and thus allows also the use of the solvents again for upstream polymer synthesis achieving the high purity requirements in a closed-loop process.