Journal of Chemical Engineering & Its Applications

Volume 2 Issue2

A Review Paper on Emulsion Polymerization of Vinyl Acetate

SandeepTripathi1, Shahida Anjum2, Ashwini Sood3

Department of Chemical Engineering
H.B.T.U., Kanpur
Corresponding Authors: sandeeptripathi13@gmail.com1, shahidaanjumansari13@gmail.com2,
sood.ashwini@rediffmail.com3

Abstract
Vinyl acetate has drawn attention of the research community since early
60s and it has increased manifold in recent years. This review paper aims
at exploring the use and work that had been done on vinyl acetate. Many
scientists have much work on vinyl acetate. This review paper covering the
work on vinyl acetate from 1962 to 2014.Formula of vinyl acetate is
C4H6O2 where the Molar mass is 86.09 g/mol. Boiling point of vinyl
acetae is 72.7 °C and having the Density is 934 kg/m³.

Keywords: Vinyl acetate, Emulsion, Polymerization techniques,

INTRODUCTION for “to milk” as milk is an emulsion of

1.1. An emulsion is a mixture of two or
more liquids that are normally immiscible
(Unmixable or unblendable). Emulsions
are part of a more general class of two-
phase systems of matter called colloids.
Although term colloids and emulsion are
sometimes used interchangeably, emulsion
should be used when both phases,
dispersed and continuous, are liquid. The
word emulsion comes from the Latin word
milk fat and water [1].
1.2. Two liquids can form different types
of emulsions. As an example, oil and
water can form, firstly, an oil-in –water
emulsion, where the oil is the dispersed
phase, and water is the dispersion
medium. Secondly, they can form a water-
in-oil emulsion, where water is the
dispersed phase and oil is the external

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phase. Multiple emulsions
possible, including a “water-in-oil-in-
water” emulsion.
1.3. Polymerization Techniques:
 Addition polymerization
 Bulk polymerization
 Solution polymerization
 Suspension polymerization
 Emulsion polymerization
 Condensation polymerization
 Melt polycondensation
 Solution polycondensation
1.12. Emulsion polymerization: [2]
It is a type of radical polymerization that
usually starts with an
incorporating water, monomer,
surfactant. The most common type of
emulsion polymerization is an oil-in-water
emulsion, in which droplets of monomer
(the oil) are emulsified (with surfactants)
in a continuous phase of water. Water-
soluble polymers, such
polyvinyl alcohols or
celluloses, can also be used to act as
emulsifiers/stabilizers. The
“emulsion polymerization” is a misnomer
that arises from a historical
misconception. Rather than occurring in
emulsion droplets, polymerization takes
place in the latex particles that form
spontaneously in the first few minutes of
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Journal of Chemical Engineering & Its Applications
Volume 2 Issue2
are also the process. These latex particles are
typically 100 nm in size, and comprise
many individual polymer chains. The
particles are stopped from coagulating
with each other because each particle is
surrounded by the surfactant („soap‟); the
charge on the surfactant repels other
particles electrostatically. When water-
soluble polymers are used as stabilizers
instead of soap, the repulsion between
particles arises because these water-
soluble polymers form a „hairy layer‟
around a particle that repels other
particles, because pushing particles
together would involve compressing these
chains.
emulsion
1.14. Emulsion polymerization is used to
and
manufacture several commercially
important polymers. Many of these
polymers are used as solid materials and
must be isolated from the aqueous
dispersion after polymerization. In other
cases the dispersion itself is the end
as certain
product. A dispersion resulting from
hydroxyethyl
emulsion polymerization is often called
latex (especially if derived from synthetic
name
rubber) or an emulsion (even though
“emulsion” strictly speaking refers to a
liquid in water). These emulsions find
applications in adhesives, paints, paper
coating and textile coatings. They are
finding increasing acceptance and are
 Journal of Chemical Engineering & Its Applications
Volume 2 Issue2

preferred over solvent-based products in World War II, efficient methods for
these applications as a result of their eco- production of several forms of synthetic
friendly characteristics due to the absence rubber by emulsion polymerization were
of VOCs (Volatile Organic Compounds) developed, but relatively few publications
in them. in the scientific literature appeared; most
disclosures were confined to patents or
1.15. History were kept secret due to wartime needs.
The early history of emulsion
polymerization is connected with the field After World War II, emulsion
of synthetic rubber. The idea of using an polymerization was extended to
emulsified monomer in an aqueous production of plastics. Manufacture of
suspension or emulsion was first dispersions to be used in latex paints and
conceived by workers at Bayer, before other products sold as liquid dispersions
World War I, in an attempt to prepare commenced. Ever more sophisticated
synthetic rubber. The impetus for this processes were devised to prepare
development was the observation that products that replaced solvent- based
natural rubber is produced at room materials. Ironically, synthetic rubber
temperature in dispersed particles manufacture turned more and more away
stabilized by colloidal polymers, so the from emulsion polymerization as new
industrial chemists simply tried to organometallic catalysts were developed
duplicate these conditions. The Bayer that allowed much better control of
workers used naturally occurring polymers polymer architecture.
such as gelatin, egg albumin, and starch to
stabilize their dispersion. By today‟s Theory
definition these were not true emulsion The first successful theory to explain the
polymerizations, but suspension distinct features of emulsion
polymerizations. polymerization was largely developed by
Smith and Ewart,[3] and Hawkins[4] in
The first “true” emulsion polymerizations, the 1940s, based on their studies of
which used a surface- active agent and polystyrene. Smith and Ewart arbitrarily
polymerization initiator, were conducted divided the mechanism of emulsion
in the 1920s to polymerize isoprene. Over polymerization into three stages or
the next twenty years, through the end of intervals. Subsequently it has been

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 Journal of Chemical Engineering & Its Applications
Volume 2 Issue2

recognized that not all monomers or  The total surface area of the micelles
systems undergo these particular three is much greater than the total surface
intervals. Nevertheless, the Smith-Ewart area of the fewer, larger monomer
description is a useful starting point to droplets; therefore the initiator
analyze emulsion polymerizations. typically reacts in the micelle and
not the monomer droplet.
The Smith-Ewart-Harkins theory for the
mechanism of free-radical emulsion  Monomer in the micelle quickly
polymerization is summarized by the polymerizes and the growing chain
following steps: terminates. At this point the
monomer-swollen micelle has turned
A monomer is dispersed or emulsified in a into a polymer particle. When both
solution of surfactant and water forming monomer droplets and polymer
relatively large droplets of monomer in particles are present in the system,
water. this is considered Smith-Ewart
Interval 2.
Excess surfactant creates micelles in the
water.  More monomer from the droplets
diffuses to the growing particle,
Small amounts of monomer diffuse where more initiators will eventually
through the water to the micelle. react.

A water-soluble initiator is introduced into  Eventually the free monomer

the water phase where it reacts with droplets disappear and all remaining
monomer in the micelles. (This monomer is located in the particles.
characteristic differs from suspension This is considered Smith-Ewart
polymerization where an oil-soluble Interval 3.
initiator dissolves in the monomer,
followed by polymer formation in the  Depending on the particular product
monomer droplets themselves.) This is and monomer, additional monomer
considered Smith-Ewart Interval 1. and initiator may be continuously
and slowly added to maintain their

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 Journal of Chemical Engineering & Its Applications
Volume 2 Issue2

levels in the system as the particles to include more than one growing chain
grow. per particle, however, the growing chains
per particle is still considered to be very
 The final product is a dispersion of low.
polymer particles in water. It can
also be known as a polymer colloid, Because of the complex chemistry that
a latex, or commonly and occurs during an emulsion polymerization,
inaccurately as an „emulsion‟. including polymerization kinetics and
particle formation kinetics, quantitative
Smith-Ewart theory does not predict the understanding of the mechanism of
specific polymerization behavior when the emulsion polymerization has required
monomer is somewhat water-soluble, like extensive computer simulation. Gilbert has
methyl methacrylate or vinyl acetate. In summarized a recent theory.[6]
these cases homogeneous nucleation
occurs; particles are formed without the The three stages of emulsion
presence or need for surfactant polymerization:
micelles.[5]
Stage I:
High molecular weights are developed in  The monomer diffuses to the empty
emulsion polymerization because the micelle from droplet
concentration of growing chains within
each polymer particle is very low. In  Polymerization initiated in micelles
conventional radical polymerization, the to become polymer particles
concentration of growing chains is higher,
which leads to termination by coupling,  New particles are generated as
which ultimately results in shorter micelles are consumed
polymer chains.
 This stage lasts for conversion ~ 0-
The original Smith-Ewart-Hawkins 15%
mechanism required each particle to
contain either zero or one growing chain.
Improved understanding of emulsion
polymerization has relaxed that criterion

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 Journal of Chemical Engineering & Its Applications
Volume 2 Issue2

Figure 2: Stage 1 of emulsion polymerization

Figure 3: Stage 2 of emulsion polymerization

Stage II: Stage III:

 No more surfactant available to  This stage occurs when conversion
generate new particles π ~ 40-60%

 Monomer diffuses into now a  All the monomers exist in particles

constant number of particles to
maintain some equilibrium
monomer covalent chain with in the
particle

 The monomer reservoir drops get

slowly consumed

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 Journal of Chemical Engineering & Its Applications
Volume 2 Issue2

Figure 4: Different stages in polymerization rate

Review paper from 1962 to 2014.
Napper et al. [7] described in 1962 that
with unstirred systems in the absence of
added stabilizing agents, the polymer is
formed as a gel like mass, and the
monomer is adsorbed onto the polymer
but does not dissolve in it. Polymerization
probably proceeds simultaneously in the
aqueous phase and on the surface of the
precipitated polymer. In the case of vinyl
acetate, the polymer is insoluble in water
but the monomer and polymer are
completely miscible, and so conditions are
different from those in the acrylonitrile-
water system seem likely to prevail.
was found to be linear with the square of
the time over a considerable range, despite
the fact that a constant number of polymer
particles were attained by about 5%
conversion. The auto acceleration
observed could be described to an increase
in the average number of free radicals per
particle as polymerization proceeds. This
paper reports the effects of added soaps of
different types at concentrations below the
critical micellar concentration (c.m.c.),
i.e., in the absence of micelles. Some
interesting differences found between the
anionic and cationic types threw light
upon the polymerization process.

Napper et al.[8] depictedin 1962 that the Breitenbach et al.[9] illustrated in 1970
kinetics of the polymerization of vinyl that the conventional picture of emulsion
acetate in aqueous peroxydisulfate polymerization as a three-stage process
solution suggest that polymerization with localisation of polymer formation and
occurs primarily within the polymer growth in discrete micelles and particles is
particles which form as a stable not completely confirmed by kinetic
suspension. The percentage conversion measurements. In many cases no particle

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formation period according to Smith-
Ewart theory can be observed. The
monomer concentration in true aqueous
solution seems nearly always to be high
enough to enable the initiation reaction to
take place in the aqueous phase. Newly
formed polymer molecules
stabilised by the emulsifier or may be
adsorbed on existing polymer particles.
Chain transfer reactions are of high
importance for free radical
between particles and solution. It seems
possible that chain termination to a high
degree occurs in the aqueous phase. In the
case of vinyl acetate polymerization the
dissolution of growing chains gives
additional homogeneity to the system.
Noro K.[10] described in 1970 that by
adding MeOAc to the hydrolysis system,
the intramolecular distribution of residual
acetate groups is changed.
hydrolysis system becomes
heterogeneous, the intermolecular
distribution of residual acetate groups also
becomes more broad. From fractionation
experiments, it is found
intramolecular distribution seems to have
a great influence on the properties of PV-
OH. PV-OH with
intramoleculardistribution, increases the
viscosity and the stability against addition
of sodium sulphate for PV-OAc emulsions
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Journal of Chemical Engineering & Its Applications
Volume 2 Issue2
made with this type of PV-OH containing
carbonyl groups shows increased PV-OH.
Viscosity of the emulsion obtained and
improved freeze-thaw stability. In order to
ascertain the relation between the number
of acrolein units in the modified PV-OH
may be and the freeze-thaw stability, some
experiments were carried out, but results
were inconclusive.
transfer Nomura et al.[11] illustrated in 1971 a
mechanism of a rapid escape of
monomeric radicals produced by the
chain – transfer reaction which occurs
dominantly in the polymer particles. Semi-
empirical equations were proposed for the
estimation for the average number of
radicals per particle over the whole range
of monomer conversion. It was also
proposed that the reaction locus in the
emulsion polymerization of vinyl acetate
As the was located in the polymer particles, and
more to explain quantitatively the role of the
polymer particles by a mechanism
involving the rapid escape of polymerizing
radicals out of the polymer particles.
that
Brian et al.[12] depicted in 1973 that high
conversion of monomer to polymer in the
'blocky' emulsion polymerization of vinyl acetate
by redox initiation has been achieved
using ammonium persulphate, a reducing
agent and a series of variable-valency
 Journal of Chemical Engineering & Its Applications
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metal ions. To obtain maximum homopolymerization in aqueous acidic

conversion, a metal soap with suitable emulsion. Water solubility does not appear
solubility in the monomer must be used, to be the overriding consideration.
and the solubility of the metal soap in the Activity of the radical would seem to be
polymerization layer must be adjusted, most important. Copolymerization with
e.g. by means of the pH, during the monomers not undergoing
process. With sodium dodecyl benzene homopolymerization in this system
sulphonate as the anionic surfactant, and a produces good yields of copolymers low
final emulsion pH of 5 to 6, the efficiency in vinyl acetate concentration. Vinyl
of the metal ions fell in the order Ti3+> acetate plays a vital role in the initiation
Fe3+> Co2+> Mn2+> Cu2+, process in electro initiated
corresponding to the order of decreasing copolymerizations but is itself
solubility of their soaps in vinyl acetate incorporated only to a very limited extent
monomer. in the growing polymer chains. It would
appear that vinyl acetate is essential in
Vivian et al.[13] described in 1975 that the these copolymerizations in order that the
polymerization proceeds by a mechanism “vinyl acetate-hydrogen‟‟ radicals, the true
different from that of most vinyl chain initiators, can be formed. The other
monomers. In particular, the rates are monomers do not possess a sufficient
approximately zero order on monomer electron affinity for their “monomer-
from 20 to 85 % conversion with only a hydrogen‟‟ radicals to be formed.
minor dependence on the soap
concentration and the number of particles. Nomura et al[15] clarified in 1978 that the
The dependence of the rate on the initiator dissolved monomer in the water phase
concentration varies with different affects not only the monomer r
investigators from 0.5-1 .0 order. The concentration in the polymer particles but
results are discussed in terms of various also the rate constant of termination in the
current theories and an attempt is made to polymer particles through the change in
rationalise them in a reasonable way. the weight ratio of monomer to polymer in
the polymer particles. The polymerization
Tidswell et al[14] described in 1975 that rate in this system can be explained by the
vinyl acetate and vinyl n-caproate are the case 3 kinetics in the Smith and Ewart
only ones capable of electro initiated theory worked out for emulsion

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 Journal of Chemical Engineering & Its Applications
polymerization when the effect of
dissolved monomer in water was taken
into consideration. The conclusions
obtained in this study will be expected to
apply to emulsion polymerization and
polymerization of other water-soluble
monomers in aqueous media
Kiparissides et al[16] reported in 1979 a
theoretical investigation of the emulsion
polymerization of vinyl acetate in a
continuous stirred tank reactor operating
under conditions of sustained oscillations.
Model of two levels of sophistication were
developed: a comprehensive model that
solves for the age distribution function of
polymer particles and a simplified model
that assumes discrete nucleation periods.
The latter model should find use in
adaptive control of latex reactors.
Chang et al[17] described in 1981 that the
variation of the polymerization rate with
changes in particle concentration, type of
emulsifier, emulsifier concentration,
persulfate concentration, ionic strength,
and monomer volume were determined.
The rate of polymerization is dependent
on the initiator concentration to the 0.6
power, the particle concentration to the
0.12 power, and the vinyl acetate volume
to the 0•39 power; however, it is
independent of the type of emulsifier,
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Volume 2 Issue2
emulsifier concentration, and ionic
strength in the emulsion. In all cases, the
rate of the polymerization is almost
independent of monomer concentration in
the particles until 85 or 90% conversion.
Chern and Poehlein[18] developed in 1987
a kinetic model based on the reaction
mechanisms of emulsion system. The
experimental data available in the
literature were used to test the model
under various polymerization conditions.
Reasonable agreement between the model
predictions and experimental data was
observed. A kinetic model based on these
reaction mechanisms had been developed
to calculate the average number of free
radicals per particle. The desorption rate
constant is proportional to the diffusion
coefficient of the monomer –unit free
radicals and inversely proportional to the
square of the particle size. The concept of
free volume was used to relate changes in
the diffusion coefficient with conversion.
The experimental data available in the
literature were used to assess the proposed
model under various polymerization
conditions. The model predicted the
experimental data reasonably well.
The focus of the work by Lee and
Mallinson[19]in 1988 was the continuous
stirred tank emulsion polymerization of
 Journal of Chemical Engineering & Its Applications
vinyl acetate which had shown oscillatory
behavior in conversion, particle size,
molecular weight and polydispersity
during polymerization. The kinetics in
vinyl acetate emulsion polymerization
were especially complex because of chain
transfer to polymer and monomer and the
terminal double bond reaction. A non-
steady state model to predict the average
molecular weights was developed for this
polymerization system. Improved results
were achieved by inclusion of the effects
of polymer chain initiation and
termination by absorbed radicals. It was
found that the observed oscillations were
closely related to the radical diffusion and
desorption rates that were involved in a
heterogeneous initiation mechanism. The
molecular weights and polydispersities
were successfully predicted by the model.
It was found that the effective radical
diffusion coefficient in the water phase
was a key parameter in causing the
molecular weight oscillations.
Lu et al[20] described in 1989 that in the
isothermal continuous emulsion
polymerization of vinyl acetate, a steady
reactor feed stream does not usually result
in steady monomer conversion or a
constant particle size. Relationships
between d and X are not simple and the
choice of reactor start-up procedure has a
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significant effect on the course of the
polymerization. More than one time-
average value can be obtained for X and d
with a given feed stream. A gel effect is
not required to produce the oscillations in
X and d. Soon after start-up, particle
nucleation in the reactor appears to cease.
There are some similarities with the
emulsion polymerization of
methylmethacrylate but fewer with the
emulsion polymerization of styrene. Ideal
reactor models are inapplicable and future
model development must take particle
coalescence, non-classical particle
nucleation and multiple reactor states into
account.
Bataille et al.[21] conducted in 1990 a
comparative study of agitation and level of
surfactant and the effect of agitation on the
conversion in a batch emulsion
polymerization. The concentration of the
surfactant SLS had only little influence on
the polymerization rate and on the
maximum conversion if one operates at
abnormal agitation conditions and if the
concentration of the surfactant was not
exaggerated (i. e., above eight times the
CMC); it will permit a stable emulsion.
The molecular weight was affected by the
level of surfactant used as well as the
reaction time.
 Journal of Chemical Engineering & Its Applications
Volume 2 Issue2

Kozub et al[22] proposed in 1992 an on- provided by the nonlinear state estimator.
line, nonlinear inferential feedback control When the estimated instantaneous
strategy for semi-batch emulsion conditions or copolymer properties are not
copolymerization reactors. The proposed at their desired set points, feedback control
strategy features a nonlinear estimator to corrections to the computed open-loop
infer copolymer properties from indirect input trajectories are required to eliminate
noisy measurements taken from the the error. A simple modification to the
process during operation, an on-line computation of any open-loop control
implementation of optimal open-loop policy is proposed to introduce feedback
operating policies for the control of control. The modification leads to
copolymer properties and reactor decoupled, linear first-order responses to
conditions, and a feedback controller to estimated set point errors. Kn the
correct for errors in the recomputed simulation example, the nonlinear
optimal trajectories. In this paper, inferential feedback control strategy is
simulated control of the properties of shown to provide excellent control over
styrene/butadiene rubber (SBR) is copolymer properties, and is demonstrated
considered. Using knowledge of the to be robust to state initialization errors,
modelled chemical reaction mechanisms, a disturbances and model mismatch. The
procedure is proposed for developing simple and effective semi-batch control
optimal operating policies based on strategy offers a very useful alternative to
establishing conditions for maintaining computationally intensive on-line
fixed instantaneous copolymer properties optimization procedures.
or reactor conditions. Well-known
univarlate approaches are extended to the Urquiola et al[23] developed in 1993 a
multivariate case, and new policies are model to aid in the further understanding
proposed. It is shown that a wide range of of the growth of latex particles in the
copolymer property specifications can be emulsion polymerization of vinyl acetate
met through the applications of these using a polymerizable surfactant, sodium
operating policies. The open-loop feed dodecyl allylsulfosuccinate (TREM LF-
forward control trajectories required in 40). The model incorporates the main
these policies are simple to compute and, features of the system observed
therefore, can be continually recomputed experimentally: copolymerization in the
on-line using the improved state estimates aqueous phase, at the particle surface, and

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 Journal of Chemical Engineering & Its Applications
chain transfer to TREM LF-40. The
reactions at the particle/water interface
and, more specifically, the chain transfer
to TREM LF-40 leading to a decrease in
the average number of radicals per
particle, was found to be the most
significant mechanism for explaining the
difference in kinetic results found for
TREM LF-40 and its non polymerizable
counterpart. The copolymerization of
vinyl acetate with TREM LF-40 was also
shown to slow the overall polymerization
rate. However, the copolymerization alone
was not sufficient to account for the
decreased polymerization rates observed
experimentally. A combination of
copolymerization and chain transfer to
TREM LF-40 was found to provide a
good fit of the experimental results.
Gilmore et al.[24] also found in 1993 that
the various reactions at the particle / water
interface were important factors
considered responsible for the differences
observed in the presence of the reactive
surfactant, as reported in part II. Gilmore
et al. concluded that experimental
conversion and particle size data were
predicted with reasonable accuracy. Model
predictions of measurable variables
exhibit sensitivity to variables affecting
either primary ungrafted particle
nucleation or flocculation kinetics, but
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Volume 2 Issue2
were relatively insensitive to variables
affecting poly (vinyl alcohol) grafting
reactions and the resulting primary grafted
particle concentration. Semi-batch
simulations indicated that independent
increases in the vinyl acetate, poly (vinyl
alcohol), and initiator levels all increase
the primary grafted particle population.
however, that this population exceeds the
ungrafted counterpart under most
commercial polymerization conditions.
This relative insignificance of grafting
during particle nucleation was also noted
in literature data simulations where, with
appropriate parameter adjustments, the
model predictions agreed well with the
batch, thermal initiation data.
The work of Kshirsagar et al.[25]
described in 1994 an attempt to validate
this model by experimentally determining
the critical size of the oligomeric radicals
that enter particles. An experimental
strategy was devised to study these
phenomena. Polystyrene latex with a
water- insoluble inhibitor partitioned into
the polymer particles was used as seed for
secondary polymerization of vinyl acetate.
This was done to form and isolate stable
oligomers of the critical size. The presence
of vinyl acetate oligomers was detected
with Fourier transform infrared
spectroscopy and thin-layer
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chromatography. Fast atom bombardment- Kiparissides.[27] described in 1996 that

mass spectroscopy (MS) was used to synthetic polymers are produced via a
determine the molecular weights of the multitude of reaction mechanisms and
oligomers. Though it was not possible to processes, including addition (e.g. free
determine the precise size of the vinyl radical, ionic, group-transfer, Ziegler-
acetate oligomers formed, the MS results Natta coordination) and step-growth
show that the number of monomer units in polymerizations. A major objective of
the oligomers had an upper bound of 12- polymerization reaction engineering is to
14. The number of units in the oligomer of understand how the reaction mechanism,
critical size was estimated to be about 5-6. the physical transport processes (e.g. mass
The experimental strategy used in this and heat transfer, mixing), reactor
work had made it possible to determine configuration and reactor operating
the approximate size of oligomers formed conditions affect the macromolecular
in the aqueous phase during emulsion architecture (e.g. molar mass, molecular
polymerization. weight distribution, copolymer
composition distribution, branching
Tongyu et al.[26]in 1995 developed a distribution, stereo regularity, etc.) as well
model equation for calculating the radical as the morphological properties of the
desorption rate constant k0 in the polymer product (e.g. particle size
emulsion polymerization of vinyl acetate distribution, porosity, etc.). As the
and the various parameters for evaluating polymer industry becomes more
k0 were determined. Effects of reaction competitive, polymer manufacturers face
temperature, emulsifier concentration, increasing pressures for production cost
initiator concentration, monomer reductions and more stringent "polymer
conversion and phase ratio on k0 were quality" requirements. To achieve these
studied. It indicated that the desorption of goals one needs to develop comprehensive
radicals from latex particles to aqueous mathematical models capable of
phase must be taken into account in the predicting the molecular and
modeling of emulsion polymerization for morphological properties in terms of
the monomers with higher hydrophilicity reactor configuration and operating
such as vinyl acetate. conditions. These mathematical
representations can be classified into
mieroscale kinetic models, mesoscale

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physical, transport and thermodynamic persulfate-potassium metabisulfite was

models and dynamic reactor ones. The studied at 400C. The effect of the reaction
present paper provides an overview of the conditions on the rate of polymerization
different polymerization processes and was also determined. The polymerization
mathematical modeling approaches. It is proceeded smoothly until high conversion
also addresses the problems related with and yielded stable emulsions. The
the computer-aided design, monitoring apparent activation energy for the
optimization and control of polymerization system was calculated and
polymerization reactors. the effect of some inorganic substances on
the rate of polymerization was also
Tauer et al[28] described in 1997 that the revealed. This resulted in an increase in
initial nucleation of particles occurs the conversion from 59.2 to 92.5%. The
suddenly independent of whether or not rate of polymerization increased by
emulsifier is present even if its increasing the temperature from 30 to
concentration is above the cmc. A further 500C. They also determined that the
use of CNT in emulsion polymerization viscosity average molecular weights of the
may lead to models that will be able to polymers increased and the rate of
contribute to a better understanding of polymerization decreased when
heterogeneous nucleation, secondary electrolytes were used. The emulsifier-
particle nucleation, and capture of free emulsion polymerization of vinyl
oligomers by particles. acetate was carried out in the absence or in
the presence of some electrolytes such as
Moustafa et al.[29] investigated in 1997 sodium chloride, calcium chloride,
redox initiation systems had variable aluminum chloride, sodium sulphate, and
effects on the rate of emulsion ammonium phosphate at 500C using
polymerization of vinyl acetate and on the potassium persulphate-sodium bisulphate
activation energy of the polymerization as a redox initiation system.
reaction. They also found that some
parameter affect the emulsifier-free Shaffie et al.[30] studied in 1997 the effect
emulsion polymerization of vinyl acetate. of different redox systems of different
The kinetics of emulsifier-free emulsion oxidizing agents (cations) such as
polymerization of vinyl acetate using the potassium persulfate (PPS), sodium
redox initiation system of potassium persulfate (SPS) and ammonium

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persulfate (APS) on the course of decrease with increasing emulsifier

emulsion polymerization of vinyl acetate
by using the sedimentation method.
Finally, the activation energies of these
reactions for potassium, sodium and
ammonium persulfate were found to be
0.84*104, 1.92*104 and 6.68*104 J/mol,
respectively. The rate of polymerization
was found to be dependent on the initiator
concentration to the powers 1.04, 1.02 and
0.34, respectively.
Ayoub et al.[31] evaluated in 1997 the
effectiveness of polyvinyl acetate-block-
methoxypolyoxyethelene (PVAc-b-
MPOE) copolymer as a non-ionic
emulsifier in emulsion polymerization of
vinyl acetate. The emulsion
polymerization of vinyl acetate initiated
by sodium persulphate as an initiator in
the presence of non-ionic
(polyoxyethylene POE type) emulsifier
had been kinetically investigated. The rate
of polymerization was found to be
proportional to the 0.33, 0.40 and 0.44
power of the emulsifier concentration and
to the 0.71, 0.79 and 0.87 power of the
initiator concentration. The apparent
activation energies were found to be 135,
56.5 and 38 KJ mol-1 for 65 wt%, 73 wt%
and 81 wt% POE, respectively. The
particle size was observed to increase with
increasing initiator concentration and to
concentration. The reaction order with
respect to the emulsifier concentration
(number of particles versus emulsifier
concentration) was found to be 0.10, 2.05
and 0.89 for 65 wt%, 73 wt% and 81 wt%
POE, respectively.
Kemmere et al.[32] in 1998 presents an
experimental study of the influence of
recipe and process conditions on the
coagulation behavior of PS and
PVAclattices. The influence of recipe and
process conditions on the coagulation
behavior of polystyrene (PS) and
polyvinyl acetate (PVAc) lattices had been
studied. Seeded batch experiments reveal
a significant influence of electrolyte
concentration on the coagulation behavior
of both PS and PVAclattices. Within the
experimental error, no dependency of the
coagulation behavior on process
conditions, in terms of energy dissipation,
reactor scale, impeller type, and impeller
diameter, had been observed for the
reactor scales investigated. These results
indicate that coagulation behavior during
emulsion polymerization and also in the
absence of polymerization over the
process conditions.
Sayer et al.[33]in 2002 developed a
dynamic mathematical model to simulate

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 Journal of Chemical Engineering & Its Applications
emulsion polymerization reactions carried
out in a new type of reactor, the pulsed
sieve plate column (PSPC). The PSPC
was described by an axial dispersion
model that allowed one to cover the entire
range between plug flows and perfectly
mixed stirred tank reactors and, therefore,
enabled the simulation of a wide range of
operational conditions. The developed
model was validated with experimental
data of vinyl acetate emulsion
polymerization reactions. Besides
presentation of a good agreement with
experimental data at reactor start-up and at
steady-state conditions, simulation results
also showed that, at the studied
operational conditions, the homogeneous
nucleation mechanism was very important
in order to represent the polymer particle
number increase observed experimentally
along the reactor length. The developed
model was also used to test different start-
up procedures and reaction temperatures.
Sood[34] studied in 2004 the effects of the
operating parameters (the initial initiator
amount; the initial emulsifier amount; the
monomer addition mode: batch or semi-
batch; and the monomer addition rate
under “monomer-starved conditions” for
the control of particle size distribution)
through a model that simulates batch and
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Volume 2 Issue2
semi-batch reactor operations in
conventional emulsion polymerization.
The population balance model
incorporates both the nucleation stage and
the growth stage. The full PSDs were
reported, which have normally been
omitted in earlier studies. It was shown
through simulations that the broadness of
the distributions, both initial (obtained
after the end of nucleation) and final (after
complete conversion of monomer), can be
controlled by the initial initiator amount
and the emulsifier amount. The higher
initiator amounts and the lower emulsifier
amounts favor narrower initial and final
distributions. The shape of the initial
PSDs and the trends in the average size
and range were preserved with subsequent
addition of monomer in the batch or in the
semi-batch mode, although the final PSD
was always considerably narrower than
that of the initial PSD.
The addition of monomer in the semi-
batch mode gave narrower distribution
compared to that of the batch mode, and
also, lower monomer addition rates gave
narrower distributions (larger average
sizes), which was a new result. It was
further shown through simulations that,
under monomer starved conditions, the

reaction rate closely matched
monomer feed rate.
Fernandes et al.[35]in 2004 used neural
network (NNs) technology for
optimization of emulsion polymerization
processes. The procedure presented in this
paper combined a mathematical model
with a NN that predicted appropriate
operating conditions for the reactor with a
maximum error of 5%. The specific
example was with the emulsion
polymerization of vinyl acetate. Results
indicated that training the NN with many
random points might be better than
training it with data taken from an
experimental factorial design.
The study of Suzuki et al.[36]in 2006
clarified the influence of additives on the
grafting phenomenon as well as the
particle behavior more precisely, They
carried out a model emulsion
polymerization of vinyl acetate (VAc) in a
1% aqueous solution with ammonium
persulfate (APS) using poly
alcohol) as a protective colloid in the
presence of additives. The addition of
alcohol to the system remarkably affected
the particle formation, especially grafting.
This was thought to be attributed to
competition between hydrogen abstraction
from PVA and alcohol with a sulfate
radical. Especially, the addition of acetone
18 Page 1-26 © MANTECH PUBLICATIONS 2017. All Rights Reserved
Journal of Chemical Engineering & Its Applications
Volume 2 Issue2
the to the system decreased grafting to a great
extent, resulting in the number of polymer
molecules in a polymer particle. This
the result was thought to arise from a
combination of electron abstraction from
acetone with a sulfate radical and the
chain-transfer reaction of the propagation
radical with acetone.
Arora et al.[37] investigated in 2007 a
dynamic model of emulsion
polymerization processes by the inclusion
of vaporization from the liquid phases in
the reactor to the gaseous phase. The
multi-component gas-liquid mass transfer
phenomenon was described by a set of
algebraic equations which were solved by
an iterative procedure. The vaporization
fluxes were described by Maxwell-
Stefan‟s diffusion equations. Based upon
the extended model, a novel operation
strategy was developed. By controlled
vaporization, additional heat was removed
from the reaction system. This makes it
(vinyl possible to extend the restrictions imposed
by the limited heat removal by the cooling
jacket considerably. Simulation results are
presented for the homopolymerization of
vinyl acetate in an industrial scale reactor
operated in semi-batch mode. The results
showed that a significant amount of heat
could be removed by evaporative cooling.
This work aimed at maximizing the
 Journal of Chemical Engineering & Its Applications
Volume 2 Issue2

productivity of emulsion particle nucleation and particle growth,

homopolymerization processes. that are the major determinants of the latex
PSD were modeled in detail. the model is
The model of Miteva et al.[38]in 2008 was applicable to situations when the initial
designed to increase the production rate of emulsifier level is above cmc when
the polymerization process in MITOL coalescence is absent and micellar
factory in Sezana (Slovenia). The model nucleation is the dominant nucleation
had been validated on a new set of real mechanism. The model predictions were
data taken from the polymerization plant, in close quantitative agreement with the
while keeping quality parameters at the experimental data for the emulsion
desired values. For this purpose a model polymerization of styrene as taken from
based on differential and algebraic the literature. The model‟s reliability was
equations (DAE) had been already demonstrated by successful simulation of
constructed. The model was intended to the experimental data for a number of
take over the role of a soft sensor, being variables.
able to provide estimates of the given
process outputs. Miteva et al.[30] derived A detailed model of emulsion
an extended version of the model in order polymerization, accounting for dosing
to reach fully predictive capabilities. By strategies, temperature control modes,
using modeling from first principles volume variations, radical diffusion
(energy balance), the dynamics of the (inside and outside the micelle/polymer
temperature was derived as a function of particles) and different mechanisms of
the concentrations of reacting chemicals. particle nucleation was developed by
The preliminary simulation results based Copelli et al.[40]in 2013. A non-stationary
on real plant data, derived in gPROMS numerical approach based onto the Smith-
environment, were presented. Ewart theory had been employed to
compute the average number of radicals
Sood[39]in 2008 predicted the evolution per particle. Finally, a series of
of the latex PSD in an emulsion experiments on the emulsion
polymerization reactor by developing and polymerization of vinyl acetate had been
validating a mathematical model that was carried out in an indirectly cooled semi-
formulated around the population balance batch reactor (RC1, 1L, Mettler Toledo) to
approach. The two important phenomena, validate the model.

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 Journal of Chemical Engineering & Its Applications
Volume 2 Issue2

Chen et al[42] described in 2013 that the

Yamak[41] described in 2013 the particle nucleation period can be
scientific and industrial importance of the prolonged by either decreasing Ra or
emulsion polymerization and vinyl acetate increasing [S]. The results indicate that the
based emulsion polymers from past to size of particles at the end of nucleation is
present. Firstly, the basic issues of almost independent of surfactant
conventional emulsion polymerization concentration but varies with Ra 1/3. The
were given. Its ingredients, kinetics and PSD of particles at the end of nucleation
mechanisms were explained in detail. showed only a slight change with [S] but
Other emulsion polymerization methods significantly narrowed with decreasing Ra.
including micro-, mini- and inverse- The exponent dependence of the number
emulsion polymerization were mentioned, of particles with respect to Ra and [S]
followed by the description of main were also confirmed to approach those
emulsion polymerization processes theoretically predicted, −2/3 and 1,
comprising batch, semi continuous, respectively. The molecular weight of
continuous and seeded, and their polymer decreased with decreasing rate of
application types. Secondly, the emulsion monomer addition but remained
polymerization of vinyl acetate was given. unchanged with surfactant concentration .
The characteristic feature of vinyl acetate The molecular weight of the particles is
monomer, its emulsion polymerization proportional to their size : M̅n∝ Vparticle.
conditions, and the main properties of its Secondary radical entry was found to be
homopolymer latex were summarized. the dominant mechanism of chain
Finally, the emulsion copolymerizations of termination during nucleation. A simple
vinyl acetate with other monomers having correlation was developed which showed a
specific features and industrial importance fair success in the prediction of the pattern
were discussed briefly. The effects of the in which the polymer molecular weight
copolymerization variables and the changed with [S] and Ra.
components on the course of emulsion
polymerization and the properties of the In the paper of Franklin et al[43]in 2014
resulting copolymers were explained, The MHE technique was applied to four
which was supported by the literature experimental data sets from batch and
results. semi-batch emulsion polymerization
systems. This implemented estimator had

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 Journal of Chemical Engineering & Its Applications
Volume 2 Issue2

process and measurement noise estimation of key states and covariances

covariance matrices defined by the ALS for complex processes, which will permit
technique. Process variables, such as the improvements in the quality of the
reactor and jacket temperatures, the products in chemical process operations.
overall heat transfer coefficient and the
heat of reaction were simultaneously Discussion:
estimated. Also, the estimated conversions Poly(vinyl acetate) (PVA, PVAc,
were validated in all cases (R1–R4) using poly(ethenylethanoate): commonly
experimental measurements obtained by referred to as wood glue, white glue,
gravimetry. The close agreement between carpenter's glue,school glue, Elmer's glue
the estimated and experimental results in the US, or PVA glue) is an aliphatic
showed the success of the proposed rubbery synthetic polymer with the
approach in all the polymerization formula (C4H6O2)n. It belongs to the
problems studied. Moreover, two other polyvinyl esters family with the general
key conclusions can be drawn from the formula -[RCOOCHCH2]-. It is a type of
results presented. First, the MHE with thermoplastic [44].
statistics defined by the ALS does not
require an accurate value for the initial Properties
estimate of UA to successfully perform • The degree of polymerization of
the state estimation. As a matter of fact, no poly(vinyl acetate) is typically 100 to
empirical rules or equations, nor 5000 while its ester groups are sensitive to
additional experimental information from base hydrolysis and will slowly convert
special devices, were used in the present PVAc into polyvinyl alcohol and acetic
article for the initial UA estimate. Second, acid. Under alkaline conditions, boron
the covariance matrices determined by the compounds such as boric acid or borax
ALS method are robust enough to be cause the polymer to cross-link, forming
applied in process data sets obtained for a tackifying precipitates or toys such as
wide range of operating conditions. In Slime and Flubber. A number of
particular, the reaction systems R2, R3, microorganisms can degrade polyvinyl
and R4, which are very different in acetate; most commonly, damage is
essence, were addressed using the ALS caused by filamentous fungi however
covariances from R1. Finally, the there are also algae, yeasts, lichens and
proposed method provides accurate

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 Journal of Chemical Engineering & Its Applications
Volume 2 Issue2

bacteria that have been shown to degrade the early 21st century, in part
polyvinyl acetate[45]. because the glue was stronger than
the parchment it held together.
Prepration  In handicrafts
PVAc is a vinyl polymer. Polyvinyl
acetate is prepared by polymerization of  As envelope adhesive
vinyl acetate monomer (free radical vinyl
polymerization of the monomer vinyl  As wallpaper adhesive
acetate).

 As a primer for drywall and other

Application substrates
As an emulsion in water, PVAc emulsions
are used as adhesives for porous materials, The stiff homopolymer PVAc, but mostly
particularly for wood, paper, and cloth, the more soft copolymer, a combination of
and as a consolidant for porous building vinyl acetate and ethylene, vinyl acetate
stone, in particular sandstone[46]. ethylene (VAE), is used also in paper
coatings, paintBand other industrial
Uses: coatings, as binder in nonwovens in glass
 As wood glue PVAc is known as fibers. Sanitary napkins, filter paper and in
"white glue" and the yellow as textile finishing.
"carpenter's glue" or PVA glue.
Polyvinyl acetate is also the raw material
 As paper adhesive during paper to make other polymers like:
packaging converting.
 Polyvinyl alcohol -[HOCHCH2]-:
 In bookbinding and book arts, due Polyvinyl acetate is partially or
to its flexible strong bond and non- completely hydrolysed to give
acidic nature (unlike many other polyvinyl alcohol.
polymers). The use of PVAc on the
Archimedes Palimpsest during the  Polyvinyl acetate phthalate
20th century greatly hindered the (PVAP): Polyvinyl acetate is
task of disbinding the book and partially hydrolyzed and then
preserving and imaging the pages in esterified with phthalic acid.
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 Journal of Chemical Engineering & Its Applications
Volume 2 Issue2

REFERENCES 10) Noro K., "Emulsion

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Authors’ Profile
Mr. Sandeep Tripathi has completed his M.Tech in Chemical Engineering from
HBTI Kanpur and B.Tech in Chemical Engineering from U.I.E.T,C.S.J.M University,
Kanpur (U.P) in 2012.His research focuses on Modeling & simulation, Extractive
Distillation and Reaction Engineering. Email: sandeeptripathi13@gmail.com.

Miss. Shahida Anjum working as guest faculty at Dr.A.I.T.H Kanpur, has completed
her M.Tech in Chemical Engineering from HBTI Kanpur and B.Tech in Chemical
Engineering from M.J.P.R. University, BAREILLY (U.P) in 2011.Her research
focuses on Modeling & simulation, Extractive Distillation and Reaction Engineering.
Email: shahidaanjumansari13@gmail.com.

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