Kun
Yan
ab and
Yingwu
Luo
*a
aThe State Key Laboratory of Chemical Engineering, College of Chemical and Biological Engineering, Zhejiang University, 38 Zhe Da Road, Hangzhou 310027, PR China. E-mail: yingwu.luo@zju.edu.cn
bKingfa Sci. & Tech. Co., Ltd., Guangzhou 510663, PR China. E-mail: yankunlmm@hotmail.com
First published on 6th December 2016
The seeded RAFT emulsion polymerization of styrene at low initiator concentrations was modelled using population balance equations and Monte Carlo simulations. Without any adjusting parameter, the models accurately predicted the polymerization kinetics, particle size, particle size distribution (PSD), and the characteristic changing trend of molecular weight distribution (MWD) at various initiator concentrations. An initiator concentration-dependent particle activation/deactivation process (PADeP), which played a decisive role in PSD and MWD at very low initiator concentrations, was highlighted to account for the unexpected simultaneous increase in the dispersities of PSD (PDIPS) and MWD (PDIMW) with the decrease of the initiator concentration. It was concluded that at low initiator concentrations, both PDIPS and PDIMW should be mappings of the dispersity of the number of PADeP experienced by particles during the whole polymerization course. The random nature of PADeP caused the dramatic increases in both PDIPS and PDIMW with the decrease of the initiator concentration. However, in the cases of higher initiator concentrations where the average number of PADeP was above 15, the effect of PADeP became much weaker. In such cases, PDIMW should be mainly controlled by the RAFT reaction.
More recently, reversible addition fragmentation chain transfer (RAFT) emulsion polymerization has aroused significant academic and industrial interest, since it enables the synthesis of high molecular weight polymers with pre-set molecular weight and narrow MWD, as well as nanostructured particles of block copolymers at high polymerization rates.5,6 In RAFT emulsion polymerization, the dispersity of MWD (PDIMW, defined as Mw/Mn) is not only determined by the rate of the RAFT reactions and the degree of the irreversible termination, but also affected by heterogeneous natures like the uneven distribution of the RAFT agent molecules among the particles and the particle size-dependent polymerization kinetics.7,8
In general, there is no apparent correlation between PDIPS and PDIMW since their controlling mechanisms are fundamentally irrelevant in emulsion polymerization.1 However, PDIPS and PDIMW were experimentally observed to be strongly correlated with each other in RAFT emulsion polymerization of styrene.9 In our recent study of seeded RAFT emulsion polymerization, both of them increased in a similar accelerating fashion as the initiator concentrations were reduced to much lower values than those of the conventional emulsion polymerization.9 An initiator concentration-dependent activation/deactivation process (PADeP) between active and dormant particles was ascribed to these observations. In this article, the effect of PADeP in seeded RAFT emulsion polymerization of styrene is investigated and verified via modelling. Some of the important characteristics are highlighted to give a comprehensive understanding of this process.
• Zero-one kinetics is applied to the seeded RAFT emulsion polymerization of styrene, where the entry of a radical into a latex particle already containing a growing radical leads to instantaneous termination.1,11 The coagulation term is neglected in the current model for the computational efficiency.
• RAFT agent molecules are evenly distributed among particles.
• An intermediate radical is only formed by addition reaction of the RAFT agent with a polymer radical. The addition reaction of the RAFT agent molecules with a monomer radical can be neglected.1
According to these assumptions, four types of particles are identified. The corresponding PBEs are as follows:
Particle with no free radical:1
(1) |
Particle with a polymer radical:1
(2) |
Particle with a monomer radical:1
(3) |
Particle with an intermediate radical:
(4) |
The evolution of latex particles in RAFT emulsion polymerization is predicted by these partial differential equations as a function of particle radius and polymerization time. The calculation of the parameters used in the PBEs is summarized in Table 1.
According to the material balance for the monomer, the molar mass of the unreacted monomer can be calculated by:11
(5) |
When droplets exist (in intervals I and II) in the polymerization systems, the monomer concentration in the latex particle reaches its saturation value (CP = CsatP).11 When droplets do not exist (in interval III), CP is calculated based on the material balance for the monomer:11
(6) |
The average radical number per particle is calculated by:
(7) |
The finite volume method is applied to transform the PBEs (eqn (1)–(4)) into 4 × N ordinary differential equations (ODEs), in which N is the number of the discretized radius domain with a length of Δr. The obtained ODEs were solved along with the equations for the kinetics in the aqueous phase (see in the ESI†) and the monomer mass balance equations (eqn (5) and (6)) simultaneously. The model was programmed and calculated using MATLAB software (version R2015a). The parameters used in the model are listed in Table 2.
Parameter | Value | Reference |
---|---|---|
k P | 1.259 × 107 exp(−2900/RT) | 1 |
k 1 P | 4kP | 1 |
k tr | k P × 10−0.658 exp(−23400/RT) | 1 |
d m | 923.6–0.887T | 11 |
d p | 1050.1–0.621T | 11 |
C satP | 5.8 | 1 |
C satW | 0.0056 | 1 |
D W | 1.5 × 10−7 | 1 |
M 0 | 0.104 | |
k pw | C satP/CsatW | 1 |
k add | 1.0 × 106 | 15 |
k frag | 3.0 × 105 | 15 |
N P | 8.9 × 1017 | 9 |
0 | 0.08 | 9 |
PDI0PS | 1.07 | 9 |
PDI0MW | 2.47 | 9 |
x 0 | 0.35 | 9 |
The events considered here are as follows:
Event 1. Radical entry into a latex particle.
The average time interval between radical entry is given by:
(8) |
The imaginary time for radical entry follows the most probable distribution, and can be determined by:15
(9) |
Event 2. Radical desorption from the latex particle.
The average time for radical desorption to occur is given by:
(10) |
Since the monomer radical is formed though the radical transfer to monomer reaction and only this type of radical can desorb from the latex particle, the rate coefficient of radical desorption is calculated by:1
(11) |
The imaginary time for radical desorption is determined by:15
(12) |
Event 3. Monomer radical propagation.
The average time for this event to occur is given by:
(13) |
Compared with event 2, event 3 describes the other fate of the monomer radical formed by the radical transfer to monomer reaction. Thus, the rate coefficient of monomer radical propagation instead of desorption is calculated by:
(14) |
The imaginary time for radical propagation instead of desorption is determined by:15
(15) |
The outline of the MC simulation is shown in Scheme 2. The simulation starts with a dormant particle (1 in Scheme 2). Radical entry is the only event that would happen at the beginning. The time interval for radical entry is determined. After the particle is activated, the imaginary times of three events are calculated. The event with the shortest imaginary time is chosen as the real event. And the reaction time increases by Δt (for example, Δt = tentry as radical entry is the real event). Then the number of reacted monomer units ΔNM is calculated and added to randomly selected chains (see in the ESI†). If radical entry or radical desorption is chosen as the real event, the active latex particle turns into a dormant one. And the next simulation starts from the beginning (1 in Scheme 2). On the other hand, if monomer radical propagation is chosen as the real event, the latex particle stays active and the next simulation starts from the step of determining the real event (2 in Scheme 2). Either event would generate a dead chain. The process is repeated until the final reaction time is reached. The same parameters are used as shown in Table 2. The detailed calculation process can be found in the ESI.†
Fig. 1 Effect of initiator concentration on monomer conversion and average radical number per particle (). Dots are experimental results and lines are model simulation results. Case 1 used the model described in the main text and parameters listed in Table 2. Case 2 used the same model and parameters as those in case 1, but the RAFT reaction term was removed. Case 3 used the same model and parameters as those in case 1, but ktr was set as 0.097 L mol−1 s−1. (a) Evolutions of monomer conversion with polymerization time. (b) Evolutions of with monomer conversion. |
It was reported that in RAFT (mini)emulsion polymerization, the RAFT reaction could reduce due to the existence of the RAFT intermediate radicals.16 However, the RAFT agent used in the current case (trithiocarbonate) has a much weaker retardation effect than those in the literature which used 1-phenylethylphenyl dithioacetate (PS-PEPDTA) and 2-cyanoprop-2-yl dithiobenzoate (PS-CPDB) as the RAFT agents.16,17 The effect of the RAFT reaction on should be weakened. In case 2, the model simulations were conducted using the same parameters but without the RAFT reaction (nPXP1 was removed from the present model). As seen in case 2 of Fig. 1, the polymerization rates and s only slightly increase compared with those in case 1, but still show apparent deviations from the experimental results, suggesting that the deviation should not be caused by the RAFT reaction.
In cases 1 and 2, the well-accepted value of ktr in the conventional radical polymerization of styrene (0.0292 L mol−1 s−1) was used. However, in our previous study,18 the ktr in RAFT emulsion polymerization of styrene was estimated to be only 1/3 of the well-accepted value for the conventional radical polymerization. Considering that the desorption of the monomer radical should be a source of radical loss for the latex particles at low initiator concentrations,19 it is very likely that low values might have resulted from the higher ktr value. So in case 3, ktr was reset at 0.097 L mol−1 s−1, which was recently estimated from RAFT emulsion polymerization of styrene.18 The simulation results are shown in case 3 of Fig. 1. Interestingly, the simulated evolutions of monomer conversion with polymerization time are in good agreement with the experimental results. The predicted values are higher compared with those in cases 1 and 2, and agree well with the experimental data. It must be pointed out that no adjusting parameters were used in the model simulations. So it is evident that ktr in RAFT emulsion polymerization of styrene should be much lower than that in the conventional radical polymerization. The fact that RAFT reactions could suppress the radical chain transfer to monomer reaction is unexpected. However, it has been proposed that the RAFT reaction might suppress the radical transfer to poly(butyl acrylate) reaction.20–25 The value of 0.097 L mol−1 s−1 for ktr is used for the rest of the model simulations.
The poor agreement between experimental data and model predictions at low initiator concentrations should be ascribed to the inaccuracy of the model input. It is noted that the MC simulations require the latex particles to be calculated one-by-one. However, it is impossible to acquire the accurate MWD for each particle from experimental methods. The MWD input in the simulation was obtained from the GPC result, which represented the polymer chains of all the latex particles in the polymerization systems. In the simulations, we had to assume that all particles should share an identical MWD. As a matter of fact, MWDs should be different among the particles. Particles nucleated at earlier time should be composed of longer chains, whereas the particles nucleated at later time should consist of shorter chains.
Comparisons of the final MWDs between the model predictions and the experimental results are shown in Fig. 3(c). It is seen that the differences between the model prediction curves and the experimental results mainly occur at low molecular weight ends and high molecular weight ends for all cases. These extremely short and long chains should originate from the differences of MWDs among the particles at the beginning of the seeded RAFT emulsion polymerizations.
In order to reveal how PADeP affects PSD and MWD, the number of activation/deactivation times (Nad) for each particle is counted along with the simulation. At the end of the polymerization, the average number of activation/deactivation times per particle (ad) is calculated. The radical entry rate decreases with the initiator concentration, which leads to the decrease in the rate of PADeP. As a consequence, ad decreases with the initiator concentration as shown in Fig. 4.
Fig. 4 Effect of initiator concentration on the average particle activation/deactivation times per particle (ad) from the model prediction. |
Fig. 5 shows the effect of ad on the final PDIMW and PDIPS. It is seen in Fig. 5(a) that the experimental PDIMW and PDIPS are well correlated with each other and simultaneously increase as ad decreases. As shown in Fig. 5(b), the model predicts exactly the same behaviours. The changing patterns of the experimental results are well predicted by the models. It is noticed that PDIMW and PDIPS increase slightly as ad decreases when ad was over 15. However, when ad dropped below 15, the increases of PDIMW and PDIPS become significant (the grey part in Fig. 5).
The effect of PADeP on PDIMW and PDIPS could be explained by the law of large numbers in probability theory. According to the law of large numbers, the average value of the results obtained from a large number of trials should be close to the expected value, and will tend to become closer as more trials are performed.26 For a specific particle, PADeP is a random event and ad is the expected value of the number of PADeP the particle will experience in the polymerization. Fig. 6 shows the distributions of Nad in the typical cases of Exp 1 and Exp 5. It is seen that the distributions of Nad can be well fitted by Gaussian distribution. The effect of the initiator concentration on the coefficient of variation for Nad (CV) is presented in Fig. 7. The calculation of CV can be found in the ESI.† CV increases dramatically with the decrease of the initiator concentration. In other words, the distribution of Nad broadens as the initiator concentration decreases, which obeys the law of large numbers. Fig. 8 shows the relationships of PDIMW and PDIPS with CV. An approximately linear correlation is found between PDIMW/PDIPS and CV. It is clear that both PDIMW and PDIPS should be the mappings of the dispersity of Nad.
Fig. 7 Effect of initiator concentration on the coefficient of variation for the number of the activation/deactivation times (CV). |
Fig. 8 Effect of the coefficient of variation for the number of the activation/deactivation times (CV) on dispersities of molecular weight distribution (PDIMW) and particle size distribution (PDIPS). |
C P | Monomer concentration in the latex particle, mol L−1 |
C W | Monomer concentration in the aqueous phase, mol L−1 |
C XP | RAFT agent concentration in the latex particle, mol L−1 |
CV | Coefficient of variation for the number of activation/deactivation times per particle |
d m | Density of monomer, g L−1 |
d n | Number average diameter, nm |
d p | Density of polymer, g L−1 |
d v | Volume average diameter, nm |
D W | Diffusion coefficient for monomer radicals, dm2 |
[E·] | Aqueous phase concentration of monomer radicals, mol L−1 |
[I] | Initiator concentration, mol L−1 |
[IMi·] | Aqueous phase concentration of oligomeric radicals, i = 1,2,...,z, mol L−1 |
[R] | RAFT agent concentration, mol L−1 |
GPC | Gel permeation chromatography |
G(r) | Growth rate for latex particles, L s−1 |
k des | Rate coefficient of radical desorption, s−1 |
k dM | Desorption rate coefficient of monomer radicals, s−1 |
k add | Addition rate coefficient, L mol−1 s−1 |
k frag | Fragmentation rate coefficient, s−1 |
k e | Entry rate coefficient of oligomeric radicals, L mol−1 s−1 |
keE | Re-entry rate coefficient of monomer radicals, L mol−1 s−1 |
k prop | Rate coefficient of the monomer radical propagation instead of desorption, s−1 |
k P | Propagation rate, L mol−1 s−1 |
k 1P | Monomer radical propagation rate, L mol−1 s−1 |
k pw | Partition coefficient of the monomer between the water and polymer phases |
k tr | Rate coefficient of radical chain transfer to monomer, L mol−1 s−1 |
k tr,RAFT | Rate coefficient of RAFT reaction, L mol−1 s−1 |
MWD | Molecular weight distribution |
MC | Monte Carlo |
M 0 | Molar mass of monomer unit, g mol−1 |
M n | Number average molecular weight, g mol−1 |
M w | Weight average molecular weight, g mol−1 |
N ad | Number of activation/deactivation times per particle |
ad | Average number of activation/deactivation times per particle |
ΔNM | Number of reacted monomer units |
N P | Particle number, Llatex−1 |
Average radical number per particle | |
n M | Molar mass of the unreacted monomer, mol L−1 |
n 0 | Population density function of particle with no free radical, mol L−1 dm−1 |
n m1 | Population density function of particle with a monomer radical, mol L−1 dm−1 |
n p1 | Population density function of particle with a polymer radical, mol L−1 dm−1 |
n PXP1 | Population density function of particle with an intermediate radical, mol L−1 dm−1 |
N A | Avogadro's number |
PADeP | Particle activation/deactivation process |
PBE | Population balance equation |
PDIPS | Dispersity of particle size distribution |
PDIMW | Dispersity of molecular weight distribution |
r | Radius of unswollen latex particles, dm |
Δr | Length of discretized radius domain, dm |
r s | Radius of swollen latex particles, dm |
t | Reaction time, s |
Δt | Reaction time increment, s |
des | Average time for radical desorption, s |
t des | Imaginary time for radical desorption, s |
entry | Average time interval between the radical entries, s |
t entry | Imaginary time for the radical entry, s |
prop | Average time for monomer radical propagation instead of desorption, s |
t prop | Imaginary time for the radical propagation instead of desorption, s |
V S | Swollen volume of the latex particle, L |
V W | Volume of the aqueous phase, L |
y | A homogeneous random number between 0 and 1 |
z | Critical degree of polymerization |
ρ | Overall entry rate, s−1 |
ρ initiator | Entry rate for initiator-derived radicals, s−1 |
ρ re-entry | Entry rate for monomer radicals, s−1 |
Footnote |
† Electronic supplementary information (ESI) available. See DOI: 10.1039/c6re00168h |
This journal is © The Royal Society of Chemistry 2017 |