Ethylene–vinyl acetate semi‐batch emulsion copolymerization: Use of factorial experiments for improved process understanding

Abstract

Abstract A good working knowledge of the mechanism and an appreciation of the effects the process variables have on the properties of interest are required for optimization and control of polymerization processes. Despite the importance of ethylene‐vinyl acetate emulsion copolymers, limited kinetic information is available. Results from a series of factorial experiments are presented here which examine the emulsion polymerization of ethylene with vinyl acetate. Copolymers of up to 32 wt % ethylene have been produced at an ethylene pressure of 500 psig and a temperature of 20°C. The effects of the process variables on the rate of polymerization, copolymer composition, particle size and number, molecular weight averages, and gel content are discussed. The kinetic results obtained suggest process improvements for the production of homogeneous copolymer. Mechanistically, the locus of polymerization has been verified as the polymer particles and little water phase polymerization was observed. © 1993 John Wiley & Sons, Inc.