Emulsion copolymerization: Kinetics model and reactor performance

Abstract

The Dow process for producing perfluorinated ionomeric membranes includes several emulsion copolymerizations involving gaseous tetrafluoroethylene and a second liquid phase monomer. The choice of the organic phase monomer depends on the desired product. The emulsion copolymerization reactor model was developed by extending the Smith‐Ewart‐Gardon theory for emulsion polymerization processes. Population balance techniques and Flory‐Huggins solution theory were applied. The resulting coupled partial differential equations were solved using the method of characteristics. The reactor model, with minimal adjustable parameters, predicts most polymerization results, including molecular weight, reaction rates in the three process stages, latex particle size, polymer composition, and the composition drift as a function of reaction time. The analysis and reactor model is used in the manufacturing process to set process conditions to obtain the desired properties in the polymer product.