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Combining ternary phase diagrams and multiphase coupled matrix-based Monte Carlo to model phase dependent compositional and molar mass variations in high impact polystyrene synthesis

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Abstract
High impact polystyrene (HIPS) production starts from a homogeneous grafting of styrene (St) on polybutadiene (PB). However, already at low St conversion, the reaction mixture becomes heterogeneous due to the incompatibility between polystyrene (PS) and PB. First a PS-rich phase appears, dispersed in a PB-rich phase, and then the situation reverses. At even higher St conversions, the PB-rich phase also includes PS occlusions (defined as a third phase). In the present work, a multiphase coupled matrix-based Monte Carlo (CMMC) model is pre-sented, tracking the molecular variations of individual molecules for the first time per phase. This is done ac-counting for (i) phase equilibria as inputted based on a literature-based ternary phase diagram for St-PB-PS mixtures, and (ii) diffusional limitations by means of apparent rate coefficients, demonstrating a preference for the composite kt model for the representation of the gel-effect. The simplified single phase model output is acceptable up to St conversions of 30 %, justifying the previous efforts on tuning modeling parameters also including model validation for high yield general purpose PS synthesis. However, at higher St conversions (up to 60 %), a single phase model predicts too high St amounts in the graft copolymer, and too low PS average chain lengths and dispersities. Furthermore, post-processing at a given St conversion reveals the contributions to the total PS log-molar mass distribution (log-MMD) from the PS-rich phase, the PB-rich phase, and PS occlusions. Moreover, the multimodality of the observed (total) log-MMD is uniquely explained based on these contributions, with specifically a more pronounced second peak due to blocked mass transfer of PS to the PS-rich phase at higher St conversions.
Keywords
Multiphase polymerization, Morphology, Grafting, Diffusional limitations, Monte Carlo, FREE-RADICAL POLYMERIZATION, CONTINUOUS BULK PROCESS, SOLVENT SYSTEMS, GRAFT-COPOLYMERIZATION, DIFFUSION-COEFFICIENTS, METHYL-METHACRYLATE, SELF-DIFFUSION, TERMINATION, EVOLUTION, STYRENE

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MLA
Figueira, Freddy L., et al. “Combining Ternary Phase Diagrams and Multiphase Coupled Matrix-Based Monte Carlo to Model Phase Dependent Compositional and Molar Mass Variations in High Impact Polystyrene Synthesis.” CHEMICAL ENGINEERING JOURNAL, vol. 481, 2024, doi:10.1016/j.cej.2023.148349.
APA
Figueira, F. L., Reyes Isaacura, P., Edeleva, M., Marien, Y., Wu, Y.-Y., Zhou, Y.-N., … D’hooge, D. (2024). Combining ternary phase diagrams and multiphase coupled matrix-based Monte Carlo to model phase dependent compositional and molar mass variations in high impact polystyrene synthesis. CHEMICAL ENGINEERING JOURNAL, 481. https://doi.org/10.1016/j.cej.2023.148349
Chicago author-date
Figueira, Freddy L., Pablo Reyes Isaacura, Mariya Edeleva, Yoshi Marien, Yi-Yang Wu, Yin-Ning Zhou, Zheng-Hong Luo, Paul Van Steenberge, and Dagmar D’hooge. 2024. “Combining Ternary Phase Diagrams and Multiphase Coupled Matrix-Based Monte Carlo to Model Phase Dependent Compositional and Molar Mass Variations in High Impact Polystyrene Synthesis.” CHEMICAL ENGINEERING JOURNAL 481. https://doi.org/10.1016/j.cej.2023.148349.
Chicago author-date (all authors)
Figueira, Freddy L., Pablo Reyes Isaacura, Mariya Edeleva, Yoshi Marien, Yi-Yang Wu, Yin-Ning Zhou, Zheng-Hong Luo, Paul Van Steenberge, and Dagmar D’hooge. 2024. “Combining Ternary Phase Diagrams and Multiphase Coupled Matrix-Based Monte Carlo to Model Phase Dependent Compositional and Molar Mass Variations in High Impact Polystyrene Synthesis.” CHEMICAL ENGINEERING JOURNAL 481. doi:10.1016/j.cej.2023.148349.
Vancouver
1.
Figueira FL, Reyes Isaacura P, Edeleva M, Marien Y, Wu Y-Y, Zhou Y-N, et al. Combining ternary phase diagrams and multiphase coupled matrix-based Monte Carlo to model phase dependent compositional and molar mass variations in high impact polystyrene synthesis. CHEMICAL ENGINEERING JOURNAL. 2024;481.
IEEE
[1]
F. L. Figueira et al., “Combining ternary phase diagrams and multiphase coupled matrix-based Monte Carlo to model phase dependent compositional and molar mass variations in high impact polystyrene synthesis,” CHEMICAL ENGINEERING JOURNAL, vol. 481, 2024.
@article{01J9KGQYNA108T605GY32GZY1A,
  abstract     = {{High impact polystyrene (HIPS) production starts from a homogeneous grafting of styrene (St) on polybutadiene (PB). However, already at low St conversion, the reaction mixture becomes heterogeneous due to the incompatibility between polystyrene (PS) and PB. First a PS-rich phase appears, dispersed in a PB-rich phase, and then the situation reverses. At even higher St conversions, the PB-rich phase also includes PS occlusions (defined as a third phase). In the present work, a multiphase coupled matrix-based Monte Carlo (CMMC) model is pre-sented, tracking the molecular variations of individual molecules for the first time per phase. This is done ac-counting for (i) phase equilibria as inputted based on a literature-based ternary phase diagram for St-PB-PS mixtures, and (ii) diffusional limitations by means of apparent rate coefficients, demonstrating a preference for the composite kt model for the representation of the gel-effect. The simplified single phase model output is acceptable up to St conversions of 30 %, justifying the previous efforts on tuning modeling parameters also including model validation for high yield general purpose PS synthesis. However, at higher St conversions (up to 60 %), a single phase model predicts too high St amounts in the graft copolymer, and too low PS average chain lengths and dispersities. Furthermore, post-processing at a given St conversion reveals the contributions to the total PS log-molar mass distribution (log-MMD) from the PS-rich phase, the PB-rich phase, and PS occlusions. Moreover, the multimodality of the observed (total) log-MMD is uniquely explained based on these contributions, with specifically a more pronounced second peak due to blocked mass transfer of PS to the PS-rich phase at higher St conversions.}},
  articleno    = {{148349}},
  author       = {{Figueira, Freddy L. and Reyes Isaacura, Pablo and Edeleva, Mariya and Marien, Yoshi and Wu, Yi-Yang and Zhou, Yin-Ning and Luo, Zheng-Hong and Van Steenberge, Paul and D'hooge, Dagmar}},
  issn         = {{1385-8947}},
  journal      = {{CHEMICAL ENGINEERING JOURNAL}},
  keywords     = {{Multiphase polymerization,Morphology,Grafting,Diffusional limitations,Monte Carlo,FREE-RADICAL POLYMERIZATION,CONTINUOUS BULK PROCESS,SOLVENT SYSTEMS,GRAFT-COPOLYMERIZATION,DIFFUSION-COEFFICIENTS,METHYL-METHACRYLATE,SELF-DIFFUSION,TERMINATION,EVOLUTION,STYRENE}},
  language     = {{eng}},
  pages        = {{15}},
  title        = {{Combining ternary phase diagrams and multiphase coupled matrix-based Monte Carlo to model phase dependent compositional and molar mass variations in high impact polystyrene synthesis}},
  url          = {{http://doi.org/10.1016/j.cej.2023.148349}},
  volume       = {{481}},
  year         = {{2024}},
}

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