Emulsion copolymerization of vinyl acetate and butyl acrylate in a tubular reactor

Emulsion polymerization has been well studied in batch systems and to a lesser extent in continuous stirred tank reactors; however, there has been very little work done with tubular reactors. The main objective of the proposed work is to study the copolymerization of vinyl acetate and butyl acrylate in a tubular reactor. Specific objectives are as follows: (1) To establish the best conditions using a tubular reactor with and without a static mixer. (2) To evaluate the effect of static mixer on the characteristics of the product, as well as on the particle size distribution in the above mentioned systems. (3) To determine the effect of operational parameters on particle size distribution and copolymer composition.; By studying copolymerization of vinyl acetate and butyl acrylate in a tubular reactor different flow regions were found in which conversion is in its maximum. The experimental data obtained show that each monomer composition in feed reaches a maximum in a flow region that is different from the others. Also it was found that the amount of butyl acrylate has a direct effect on the number of particles and on the final conversion. Lower levels of butyl acrylate and the velocity of fluid flowing inside the tube having a strong effect on the shape and the width of particle size distributions. The results obtained from copolymer composition showed that in most experiments an alternating block copolymer is formed during the reaction.; Emulsion copolymerization in presence of static mixer was evaluated. It was found that there is a flow region in which the emulsion copolymerization has maximum conversion. This region could be displaced by changing feed composition, and by the presence of a static mixer. A static mixer can change the distribution of particle size in final latex, and has strong effect on the molecular structure of the product.; The apparent reactivity ratio of the vinyl acetate with butyl acrylate were determined at different flow regions. Effect of flow rate was investigated on conversion and copolymerization rate. It was found that in each flow region, variation of mole fraction of vinyl acetate in feed has a unique behavior. Type and shape of reactor, flow rate and presence or absence of a static mixer have strong effect on the apparent reactivity ratios of vinyl acetate and butyl acrylate. In tubular reactors, the reactivity of the two monomers depends on the fluid velocity and the presence of a static mixer. (Abstract shortened by UMI.)...