A Project Report ON Modelling & Synthesis of Poly(butyl-acrylate) by Batch Emulsion Polymerization Technique Submitted in partial fulfilment of the requirements for the awards of degree of BACHELOR OF TECHNOLOGY In CHEMICAL ENGINEERING

Guided by: Submitted by:
Dr. Sushant Upadhyaya Rajat Chauhan (2010UCH176)
Assistant Professor Prabhat Pachuri (2010UCH201)
MNIT Jaipur Pushpendra Dagar (2010UCH209) Nitin Mathur (2010UCH226) DEPARTMENT OF CHEMICAL ENGINEERING
MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY JAIPUR
June 2014

MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY, JAIPUR

CERTIFICATE

This is to certify that following students of Department of Chemical Engineering, Malaviya National Institute of technology, Jaipur have undergone a project titled as “Modelling & Synthesis of Poly(butyl-acrylate) by Batch Emulsion Polymerization Technique” under my guidance. During this process, their performance is found ____________________.

Rajat Chauhan (2010 UCH 176)
Prabhat Pachaury (2010 UCH 201)
Pushpendra Dagar (2010 UCH 209)
Nitin Mathur (2010 UCH 226)

Dr. Sushant Upadhyaya Assistant Professor Dept. of Chemical Engineering MNIT Jaipur

ACKNOWLEDGEMENT |

Major project is an essential part of engineering student. The completion of this project depends upon co-operation, co-ordination and combined efforts of several sources of knowledge, energy and time. Hence we approach this matter of acknowledgement this times trying our best to give credit whenever it is due.
It is our proud privilege to express gratitude and regard for the luminous and fabulous evidence and remarkable suggestions in completing the project. We have great pleasure in expressing our deep sense of gratitude to our respectful supervisor Assistant Professor Dr.Sushant Upadhyaya, Department of Chemical Engineering. We are also thankful to Mr. Jitendra Rajput, Ph.D. scholar, for his help throughout the project.
We are also thankful to all the faculty members of the department for their support from time to time.

Rajat Chauhan
Prabhat Pachuary
Pushpendra Dagar
Nitin Mathur

ABSTRACT |

Polymers are being used in range of applications from daily life, engineering materials to agriculture, as they have high molecular weight, light weight with high tensile strength and range of properties. One of the most important polymer is Poly(butyl-acrylate), which is being used in latex paint formation and pressure sensitive adhesives (PSA) etc. Poly(butyl-acrylate) has been synthesized in laboratory using batch emulsion polymerization technique in batch reactor. Different parameters which affect the rate of formation of the polymer are discussed in the project. Effect of many parameters on the rate of polymerization like variation of monomer concentration, initiator concentration etc is studied. Testing and characterization of the synthesized polymer has been done at Central Institute of Plastics Engineering and Technology (C.I.P.E.T) laboratory Jaipur & Central Research Facility, IIT Delhi. With reference to these testing like melt flow index, density and melting point, molecular weight distribution etc., study of different properties with varying parameters has been done. A mathematical model is also developed and compared with a classical model to understand the variation of different parameters. Finally, theoretical model has been validated against the experimental results and found to be of similar nature.

Nomenclature |

Wfo= Initial weight fraction of monomer in mixture
Wm= Weight of monomer
Wsamp= Weight of sample
Wt= Total weight of mixture
Wp= Weight of polymer
X = Degree of conversion µ = Viscosity of polymer solution µ0 = Viscosity of solvent to= Efflux time required for solvent
[I] = Initiator concentration
[M] = Monomer concentration
[P] = Polymer concentration
R = Primary radical
Ri= Rate of disappearance of initiator
Rm= Rate of disappearance of monomer
Rp= Rate of formation of polymer
V = Kinetic chain length
Xn= Number avg. degree of polymerization
Mo = Molecular weight of monomer f = Initiator efficiency
Kp= Rate const. for propagation
Ktc= Rate const. for termination by combination
Ktd= Rate const. for termination by disproportionation
KtrTA= Rate const. for transfer to monomer/initiator
Kt= Overall rate const. for termination
Kd = Rate const. for initiator decomposition
KI = Rate constant for initiation
RMn• = Propagating chain radical with degree of polymerization n
RMm• = Dead polymer with Degree of polymerization m
RMn= Terminating polymer chains with degree of polymerization equal to n
RMp= Terminating polymer chains with degree of polymerization equal to p
RMnRMp= Terminating polymer chains with degree of polymerization equal to n+p
[R•] = Concentration of primary free radicals
[M•] = Total concentration of chain radicals

List of Figures |

Figure 3.0 Structure of n-butyl acrylate
Figure 3.2 Structure of Sodium oleate
Figure 3.3 Structure of water
Figure 3.4 Structure of toluene
Figure 3.5 Structure of methanol
Figure 3.6 Schematic representation of batch emulsion polymerization process
Figure 3.7 Ostwald viscometer
Figure 3.8 MFI test machine
Figure 3.9 Melting point measurements
Figure 3.10Density measurements
Figure 5.1 Degree of conversion v/s. time profile
Figure 5.2 Rate of polymerization v/s. degree of conversion profile
Figure 5.3 Rate of conversion v/s. time profile
Figure 5.3 Weight of polymer v/s. time profile
Figure 5.4 Polymer concentration v/s. time profile
Figure 5.5 Theoretical rate of monomer disappearance v/s. time
Figure 5.6 Theoretical rate of polymer formation v/s. time
Figure 5.7 Theoretical and experimental weight of polymer

List of Tables |

Table 3.0 Properties of n-butyl acrylate monomer
Table 3.1 Properties of potassium persulphate
Table 3.2 Properties of sodium oleate emulsifier
Table 3.3 Properties of water solvent
Table 3.4 Properties of benzene solubilizer
Table 3.5 Properties of methanol terminator
Table 3.6 Typical recipe for polymerization
Table 3.7 Ingredients for experimental run 1
Table 3.8 Ingredients for experimental run 2
Table 3.9 Weight of polymer for experimental run 1
Table 3.10 Weight of polymer for experimental run 2
Table 3.11 Degree of conversion and rate of polymerization for experimental run 1
Table 3.12 Degree of conversion and rate of polymerization for experimental run 2
Table 3.13 Viscosity of poly(butyl-acrylate) solution in experimental run 1
Table 3.14 Viscosity of poly(butyl-acrylate) solution in experimental run 2
Table 3.15 pH and conductivity of poly(butyl-acrylate) solution in experimental run 1
Table 3.16 pH and conductivity of poly(butyl-acrylate) solution in experimental run 2
Table 5.1 Experimental v/s. theoretical weight of polymer for experimental run 1
Table 5.2 Experimental v/s. theoretical weight of polymer for experimental run 2
Table 5.3 Rate of polymerization v/s. time for experimental run 1 and 2