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Aspiazu UO, Gómez S, Paulis M, Leiza JR. Real-Time Monitoring of Particle Size in Emulsion Polymerization: Simultaneous Turbidity and Photon Density Wave Spectroscopy. Macromol Rapid Commun 2024:e2400374. [PMID: 39018484 DOI: 10.1002/marc.202400374] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/23/2024] [Revised: 06/28/2024] [Indexed: 07/19/2024]
Abstract
Particle size evolution in seeded semibatch emulsion polymerization is monitored by two real-time monitoring techniques: online turbidity spectroscopy (TUS) and inline photon density wave spectroscopy (PDWS). An automatic dilution system that withdraws a sample from the reactor and upon dilution transfers to the measurement cell is used for the online TUS analysis. A PDWS probe is immersed in the reactor and collects inline the scattered light directly from the reacting latex. The particle sizes retrieved from TUS and PDWS are compared to offline dynamic light scattering (DLS) values. The particle size obtained by TUS is close to the intensity-average particle size obtained offline by DLS, while the particle size obtained by PDWS lies closer to the number-average particle size from DLS.
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Affiliation(s)
- Usue Olatz Aspiazu
- POLYMAT, Kimika Aplikatua Saila, Kimika Fakultatea, University of the Basque Country UPV/EHU, Joxe Mari Korta Zentroa, Donostia-San Sebastián, 20018, Spain
| | - Susana Gómez
- IRIS Technology Solutions SL. Carretera Esplugues Local 39-41, Cornellá de Llobregat, Barcelona, 08940, Spain
| | - Maria Paulis
- POLYMAT, Kimika Aplikatua Saila, Kimika Fakultatea, University of the Basque Country UPV/EHU, Joxe Mari Korta Zentroa, Donostia-San Sebastián, 20018, Spain
| | - Jose Ramon Leiza
- POLYMAT, Kimika Aplikatua Saila, Kimika Fakultatea, University of the Basque Country UPV/EHU, Joxe Mari Korta Zentroa, Donostia-San Sebastián, 20018, Spain
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Schlappa S, Bressel L, Reich O, Münzberg M. Advanced Particle Size Analysis in High-Solid-Content Polymer Dispersions Using Photon Density Wave Spectroscopy. Polymers (Basel) 2023; 15:3181. [PMID: 37571075 PMCID: PMC10421201 DOI: 10.3390/polym15153181] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/27/2023] [Revised: 07/21/2023] [Accepted: 07/24/2023] [Indexed: 08/13/2023] Open
Abstract
High-solid-content polystyrene and polyvinyl acetate dispersions of polymer particles with a 50 nm to 500 nm mean particle diameter and 12-55% (w/w) solid content have been produced via emulsion polymerization and characterized regarding their optical and physical properties. Both systems have been analyzed with common particle-size-measuring techniques like dynamic light scattering (DLS) and static light scattering (SLS) and compared to inline particle size distribution (PSD) measurements via photon density wave (PDW) spectroscopy in undiluted samples. It is shown that particle size measurements of undiluted polystyrene dispersions are in good agreement between analysis methods. However, for polyvinyl acetate particles, size determination is challenging due to bound water in the produced polymer. For the first time, water-swelling factors were determined via an iterative approach of PDW spectroscopy error (Χ2) minimization. It is shown that water-swollen particles can be analyzed in high-solid-content solutions and their physical properties can be assumed to determine the refractive index, density, and volume fraction in dispersion. It was found that assumed water swelling improved the reduced scattering coefficient fit by PDW spectroscopy by up to ten times and particle size determination was refined and enabled. Particle size analysis of the water-swollen particles agreed well with offline-based state-of-the-art techniques.
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Affiliation(s)
- Stephanie Schlappa
- Department of Physical Chemistry, innoFSPEC, University of Potsdam, Am Mühlenberg 3, 14476 Potsdam, Germany (M.M.)
| | - Lena Bressel
- Department of Physical Chemistry, innoFSPEC, University of Potsdam, Am Mühlenberg 3, 14476 Potsdam, Germany (M.M.)
| | - Oliver Reich
- Knowledge and Technology Transfer, Faculty of Science, University of Potsdam, Am Mühlenberg 3, 14476 Potsdam, Germany;
| | - Marvin Münzberg
- Department of Physical Chemistry, innoFSPEC, University of Potsdam, Am Mühlenberg 3, 14476 Potsdam, Germany (M.M.)
- Knowledge and Technology Transfer, Faculty of Science, University of Potsdam, Am Mühlenberg 3, 14476 Potsdam, Germany;
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Neves JS, Assis PHC, Machado F, D'Agosto F, Lansalot M, McKenna TFL. Bimodal high solids content latices using
RAFT
‐mediated polymerization‐induced self‐assembly and semi‐batch emulsion polymerization. J Appl Polym Sci 2023. [DOI: 10.1002/app.53867] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/17/2023]
Affiliation(s)
- Juliete S. Neves
- Laboratório de Desenvolvimento de Processos Químicos (LDPQ), Instituto de Química Universidade de Brasília, Campus Universitário Darcy Ribeiro Brasília CEP 70910‐900 Brazil
- Catalysis, Polymerization, Processes and Materials (CP2M), UMR 5128 Univ Lyon, Université Claude Bernard Lyon 1, CPE Lyon, CNRS 43 Bvd. du 11 Novembre 1918 Villeurbanne F‐69612 France
| | - Paulo H. C. Assis
- Catalysis, Polymerization, Processes and Materials (CP2M), UMR 5128 Univ Lyon, Université Claude Bernard Lyon 1, CPE Lyon, CNRS 43 Bvd. du 11 Novembre 1918 Villeurbanne F‐69612 France
| | - Fabricio Machado
- Laboratório de Desenvolvimento de Processos Químicos (LDPQ), Instituto de Química Universidade de Brasília, Campus Universitário Darcy Ribeiro Brasília CEP 70910‐900 Brazil
| | - Franck D'Agosto
- Catalysis, Polymerization, Processes and Materials (CP2M), UMR 5128 Univ Lyon, Université Claude Bernard Lyon 1, CPE Lyon, CNRS 43 Bvd. du 11 Novembre 1918 Villeurbanne F‐69612 France
| | - Muriel Lansalot
- Catalysis, Polymerization, Processes and Materials (CP2M), UMR 5128 Univ Lyon, Université Claude Bernard Lyon 1, CPE Lyon, CNRS 43 Bvd. du 11 Novembre 1918 Villeurbanne F‐69612 France
| | - Timothy F. L. McKenna
- Catalysis, Polymerization, Processes and Materials (CP2M), UMR 5128 Univ Lyon, Université Claude Bernard Lyon 1, CPE Lyon, CNRS 43 Bvd. du 11 Novembre 1918 Villeurbanne F‐69612 France
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Rust S, Pauer W. Determination of inline-particle sizes by turbidity measurement in high solid content emulsion polymerisations. JOURNAL OF POLYMER RESEARCH 2022. [DOI: 10.1007/s10965-022-03141-z] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Abstract
AbstractParticle size determination in optically dense systems requires costly techniques or dilution of collected samples. Against this background, turbidimetry was investigated as a potentially robust as well as inexpensive alternative. Emulsion copolymerisations of vinyl acetate and VeoVa10® with solid contents up to 48 wt% were examined time resolved with respect to mean particle size at different temperatures, solid contents and with different co-monomer ratios and emulsifier concentrations. The mean hydrodynamic diameters were validated by dynamic light scattering (DLS). Precise number mean hydrodynamic diameters in the range from 100 to 250 nm were obtained in-line for polyvinyl acetate dispersions with deviations in particle sizes below ± 5%. In addition, the turbidity values were recorded by means of a nephelometry process probe and thus a robust, system-related calibration was created, which was subsequently able to reliably track the number mean hydrodynamic diameter inline time-resolved.
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Jacob LI, Pauer W, Schroeter B. Influence of redox initiator component ratios on the emulsion copolymerisation of vinyl acetate and neodecanoic acid vinyl ester. RSC Adv 2022; 12:14197-14208. [PMID: 35558856 PMCID: PMC9092359 DOI: 10.1039/d2ra01811j] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/20/2022] [Accepted: 05/03/2022] [Indexed: 11/21/2022] Open
Abstract
Redox initiated emulsion polymerisation of vinyl acetate and neodecanoic acid vinyl ester was investigated at temperatures ranging from -1 °C to 87 °C (initiation temperature between -1 °C and 60 °C), using varying molar ratios of the following redox components: l-ascorbic acid, tert-butyl hydroperoxide and ammonium iron(iii) sulfate dodecahydrate as a catalyst. The high flexibility of redox initiators enables product properties, as well as space-time-yield, to be adjusted as required. Polymers being products by process, it was presumed that modifying the conversion rate would lead to a different product. However, it was shown that the reaction rate is adjustable by varying the catalyst amount without changing the product properties, such as molecular weight, particle size, glass transition temperature and polymer structure, while reducing the overall process time by 40-86% (at equimolar ratios of reducing and oxidising agent). In contrast, variation of the tert-butyl hydroperoxide content resulted in changes of the molecular weight. The influence of the initiation temperature and of the redox system on the reaction rate was determined, enabling control over the reaction rate in the whole temperature range. Meanwhile, overall process times of approximately 2-240 min and high conversions of 90-99% could be achieved. Statistical modelling confirmed the results and facilitated predictions, enabling the conversion rate to be adjusted to the desired properties. The possibility of being able to adjust the conversion rate and product properties independently of each other creates additional degrees of freedom in process design.
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Affiliation(s)
- Laurence Isabelle Jacob
- Institute for Technical and Macromolecular Chemistry, University of Hamburg Bundesstraße 45 20146 Hamburg Germany
| | - Werner Pauer
- Institute for Technical and Macromolecular Chemistry, University of Hamburg Bundesstraße 45 20146 Hamburg Germany
| | - Baldur Schroeter
- Institute of Thermal Separation Processes, Hamburg University of Technology Eißendorfer Straße 38 21073 Hamburg Germany +49 40 42878 3962
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Jacob LI, Pauer W. Scale-up of Emulsion Polymerisation up to 100 L and with a Polymer Content of up to 67 wt%, Monitored by Photon Density Wave Spectroscopy. Polymers (Basel) 2022; 14:polym14081574. [PMID: 35458324 PMCID: PMC9028448 DOI: 10.3390/polym14081574] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/31/2022] [Revised: 03/14/2022] [Accepted: 04/07/2022] [Indexed: 02/06/2023] Open
Abstract
The scale-up process of the high solid content (up to 67 wt%) emulsion polymerisation of vinyl acetate and Versa®10 from 1 L over 10 L to 100 L was investigated. An emulsion copolymerisation of vinyl acetate and neodecanoic acid vinyl ester in a molar ratio of 9:1 was carried out in a starved-fed semi-batch operation. As a radical source, a redox initiator system consisting of L-ascorbic acid, tert-butyl hydroperoxide and ammonium iron (III) sulphate was used. The process parameters, such as the required stirring speed and heat dissipation, were determined and adjusted beforehand via reaction calorimetry to ensure a successful scale-up without safety issues. In addition, the emulsion polymerisation was monitored inline by Raman (qualitative monomer accumulation), as well as Photon Density Wave spectroscopy (particle size and scattering coefficient) and temperature measurements. The data provided by Raman spectroscopy and temperature measurements revealed mixing difficulties due to an insufficient stirring rate, while the inline measurement with Photon Density Wave spectroscopy offered an insight into the development of the product properties. It proved to be reliable and precise throughout the entire scale-up process, especially compared to conventional offline methods, such as dynamic light scattering or sedimentation analysis by means of a disc centrifuge, both of which encountered issues when using higher polymer contents.
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Schlappa S, Brenker LJ, Bressel L, Hass R, Münzberg M. Process Characterization of Polyvinyl Acetate Emulsions Applying Inline Photon Density Wave Spectroscopy at High Solid Contents. Polymers (Basel) 2021; 13:669. [PMID: 33672343 PMCID: PMC7926705 DOI: 10.3390/polym13040669] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/30/2021] [Revised: 02/18/2021] [Accepted: 02/19/2021] [Indexed: 11/26/2022] Open
Abstract
The high solids semicontinuous emulsion polymerization of polyvinyl acetate using poly (vinyl alcohol-co-vinyl acetate) as protective colloid is investigated by optical spectroscopy. The suitability of Photon Density Wave (PDW) spectroscopy as inline Process Analytical Technology (PAT) for emulsion polymerization processes at high solid contents (>40% (w/w)) is studied and evaluated. Inline data on absorption and scattering in the dispersion is obtained in real-time. The radical polymerization of vinyl acetate to polyvinyl acetate using ascorbic acid and sodium persulfate as redox initiator system and poly (vinyl alcohol-co-vinyl acetate) as protective colloid is investigated. Starved-feed radical emulsion polymerization yielded particle sizes in the nanometer size regime. PDW spectroscopy is used to monitor the progress of polymerization by studying the absorption and scattering properties during the synthesis of dispersions with increasing monomer amount and correspondingly decreasing feed rate of protective colloid. Results are compared to particle sizes determined with offline dynamic light scattering (DLS) and static light scattering (SLS) during the synthesis.
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Affiliation(s)
- Stephanie Schlappa
- Department of Physical Chemistry, innoFSPEC, University of Potsdam, Am Muehlenberg 3, 14476 Potsdam, Germany; (L.J.B.); (L.B.); (R.H.); (M.M.)
| | - Lee Josephine Brenker
- Department of Physical Chemistry, innoFSPEC, University of Potsdam, Am Muehlenberg 3, 14476 Potsdam, Germany; (L.J.B.); (L.B.); (R.H.); (M.M.)
| | - Lena Bressel
- Department of Physical Chemistry, innoFSPEC, University of Potsdam, Am Muehlenberg 3, 14476 Potsdam, Germany; (L.J.B.); (L.B.); (R.H.); (M.M.)
| | - Roland Hass
- Department of Physical Chemistry, innoFSPEC, University of Potsdam, Am Muehlenberg 3, 14476 Potsdam, Germany; (L.J.B.); (L.B.); (R.H.); (M.M.)
- PDW Analytics GmbH, Geiselbergstraße 4, 14476 Potsdam, Germany
| | - Marvin Münzberg
- Department of Physical Chemistry, innoFSPEC, University of Potsdam, Am Muehlenberg 3, 14476 Potsdam, Germany; (L.J.B.); (L.B.); (R.H.); (M.M.)
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