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Department of Chemical Engineering, University of Lagos, Akoka, Yaba, Lagos 101017, Nigeria
KEYWORDS Abstract A satisfactory model for predicting monomer conversion in free radical polymerization
Free radical polymerization; has been a challenge due to the complexity and rigors associated with classical kinetic models. This
Polystyrene; renders the usage of such model an exciting endeavour in the academia but not exactly so in indus-
Acetone; trial practice. In this study, the individual and interactive effects of three processing conditions
Monomer conversion; (reaction temperature, reaction time and initiator concentration) on monomer conversion in the
Response surface solution polymerization of styrene using acetone as solvent was investigated in a batch reactor
methodology through the central composite design (CCD) model of response surface methodology (RSM) for
experimental design, modelling and process optimization. The modelled optimization conditions
are: reaction time of 30 min, reaction temperature of 120 °C, and initiator concentration of
0.1135 mol/l, with the corresponding monomer conversion of 76.82% as compared to the observed
conversion of 70.86%. A robust model for predicting monomer conversion that is very suitable for
routine industrial usage is thus obtained.
Ó 2016 The Authors. Production and hosting by Elsevier B.V. on behalf of King Saud University. This is
an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
conversion, number average molecular weight (Mn), weight starch, reaction time, reaction temperature and initiator con-
average molecular weight (Mw) and polydispersity index centration to determine their individual and interactive effects
(PDI). The classical quasi-steady state approximation fails to on the grafting percentage. They obtained satisfactory results
provide accurate results especially at high conversion owing as the actual experimental yield at optimized conditions was
to an increased viscosity of the reaction mixtures in the face very close to the value predicted by their derived model.
of continuous occurrence of initiation throughout the poly- Aroonsingkarat and Hansupalak (2013) studied the effect of
merization. This is further compounded by an increased tem- processing conditions on monomer conversion in the graft
perature for this inherently exothermic reaction, especially in copolymerization of polystyrene and rubber using response
the absence of adequate heat removal. This dynamics of the surface methodology via CCD. The reaction temperature,
host solution engenders phenomena such as gel, glass and cage time, percentage of deproteinized rubber, and amount of chain
effect which complicate kinetic modelling. Several workers transfer agent were the four variables investigated. In a related
have attempted incorporating each of these occurrences in study, Sresungsuwan and Hansupalak (2013) investigated the
their models to varying degree of success (Achilias and influence of processing conditions on the mechanical proper-
Kiparissides, 1988, 1992; Venkateshwaran and Kumar, 1992; ties of compatibilized styrene/natural rubber blend using
Frounchi et al., 2002; Keramopoulos and Kiparissides, 2002, CCD. To the best of our knowledge, no such study has been
2003; Achilias, 2007; Verros and Achilias, 2009). However, reported in the literature for solution polymerization of
these efforts largely result in models with a limited range of styrene.
application. In our previous contributions, we established the various
Recently, Garg et al. (2014a–d) derived an analytical solu- factors influencing monomer conversion in the solution poly-
tion for free radical polymerization and validated same for merization of styrene (solvent polarity, nature and concentra-
various possible scenarios to establish its general applicability. tion of initiator, monomer concentration, reaction temperature
The effectiveness of the Garg model was further corroborated and time) and their limiting values (Kehinde et al., 2013;
by its good prediction of monomer conversion in the solution Owolabi et al., 2014, 2015). In the present study, we explore
polymerization of styrene using acetone as solvent (Owolabi the effect of initiator concentration, reaction time and reaction
et al., 2014). However, the model is still fraught with the inher- temperature on monomer conversion in the solution polymer-
ent complexity and mathematical rigors of other kinetic mod- ization of styrene with acetone as solvent. Response surface
els. Another recent effort by Yong et al. (2015) to model free methodology via CCD was used to design the experiment, gen-
radical polymerization using dissipative particle dynamics erate a model and optimize the process variables. The overall
hardly address the enumerated shortcomings. There is there- objective is to obtain a model equation for routine determina-
fore the need for a robust model that is valid for all range of tion of monomer conversion as a function of these processing
conversion and yet simple enough for routine industrial appli- conditions.
cation. Such model should be based on process parameters
rather than live and dead chains as obtained in the kinetic 2. Materials and methods
models. To this end, the response surface methodology proves
invaluable. 2.1. Materials
Response surface methodology (RSM) is a statistical exper-
imental design that enables simultaneous varying of process
The chemicals used are styrene (99%) inhibited by 10–15 ppm
variables, unlike what obtains in the conventional experimen-
4-tertbutylcatechol, benzoyl peroxide (75%), methanol
tation, thereby eliciting the interaction between such variables.
(CH3OH) (99.8%), sodium sulphate (Na2SO4) (99%), sodium
It is a faster and more economical method for gathering
hydroxide (NaOH) (98%), and acetone (99.9%). All the
research results than the classic one-variable at a time or
reagents were of analytical grade, purchased from Sigma
full-factor experimentation (Krishnaiah et al., 2015). It also
Aldrich in Germany and used as received except for styrene
provides a model equation relating the response parameter
monomer which was de-stabilized as previously described
to the process variables and optimization of the same. It is a
(Kehinde et al., 2013; Owolabi et al., 2014, 2015).
veritable tool that has been deployed in a wide range of fields
namely; transesterification (Betiku et al., 2015; Muppaneni
2.2. Polymerization
et al., 2013), solvent extraction (Rai et al., 2016;
Mohammadi et al., 2016), adsorption (Ahmed and Theydan,
2014; Ezechi et al., 2015), Fenton process (Kumar and Pal, The polymerization was conducted in a 62 mm diameter round
2012), drying operations (Krishnaiah et al., 2015), carrageenan bottom pressure double neck reaction flask equipped with a
production (Bono et al., 2014) etc. reflux system. The vapourized acetone was collected by a reflux
In polymer and related fields, RSM has found application condenser. In each run, specific amount of BPO and styrene
in some reported studies (Ghasemi et al. 2010; Lee et al., monomer concentration (8.612 M) were dissolved in a desired
2011; Nasef et al., 2011; Banerjee et al., 2012; Chieng et al., volume of acetone to maintain a monomer to solvent ratio of
2012; Zheng et al., 2015; Rojo et al., 2015; Razak et al., 1:1. The reactor was maintained at the specified temperature
2015; Fattahpour et al., 2015; Hirzin et al., 2015; and time as shown in Table 2. Thereafter, the reactor was
Davoudpour et al., 2015). Razali et al. (2015) used RSM to opened up, and cooled to collect the resulting polymer solu-
study the grafting of polydiallydimethylammonium chloride tion. The clear polymer solution was added to about 3 ml of
(PolyDADMAC) to cassava starch using potassium persul- methanol in a beaker with continuous stirring to precipitate
phate (KPS) as a free radical initiator. Four variables were the polymer. The top clear solvent was decanted while the bot-
investigated via central composite design (CCD) namely; mole tom polymer samples were air-dried to remove excess solvent
ratio of diallydimethylammonium chloride (DADMAC) to and dried for 2 weeks at room conditions until a constant
24 R.U. Owolabi et al.
weight was reached. Each run was conducted in triplicates and model that correlated the response to the three process vari-
the average value taken. Monomer conversion was determined ables using a second-degree polynomial as shown in Eq. (2).
by gravimetric method as described in a previous study
(Kehinde et al., 2013). X
n X
n n1 X
X n
Y ¼ bo þ bi Xi þ bii Xii þ bij Xi Xj ð2Þ
i¼1 i¼1 i¼1 j¼iþ1
2.3. Design of experiment
where Y is the predicted response, bo is a constant coefficient,
In this study, polystyrene samples were prepared via solution bi is a linear coefficient, bii is the quadratic equation, bij is an
polymerization of styrene using acetone as solvent and benzoyl interaction coefficient, and Xi and Xj are the coded values of
peroxide (BPO) as initiator. The variables studied were the the polymerization variables. Table 2 shows the run order,
reaction temperature (X1 ), initiator concentration (X2 ), and experimental design and the observed response (% monomer
reaction timeðX3 Þ: All variables and their respective range were conversion) for the three variables and 20 experimental runs
chosen based on our earlier studies (Kehinde et al., 2013; generated. Design Expert software (minitab 16.1) is used for
Owolabi et al., 2014, 2015) as shown in Table 1. A five-level- RSM regression analysis and optimization of monomer con-
three-factor central composite design (CCD) was employed, version data with input parameters. The statistical testing of
requiring 20 experimental runs (calculated based on Eq. (1)) the model, which includes linear, quadratic and interaction
which consist of 8 factorial runs, 6 axial runs and 6 replicate coefficient, is performed by ANOVA analysis with F-test to
runs at the centre. obtain the empirical correlation between input and output
parameters. To examine the goodness of fit of the model, each
N ¼ 2n þ 2n þ Nc ¼ 23 þ 2x3 þ 6 ¼ 20 ð1Þ
term of model is tested statistically which confirmed the signif-
where N is the total experimental runs and n is the number of icance of F-values with p 6 0.05. The values of R2, adjusted R2,
variables. and predicted R2, lack of fit and adequate precision of models
The a-value for this design was fixed at 1 (face-centred), are obtained to check the quality of the suggested polynomial.
and the response for this experiment was the percent monomer The response surface plot and contour plot are drawn to visu-
conversion ðYÞ. The response was used to develop an empirical alize the input–output relationships.
Table 1 Experimental variables and their coded levels for central composite design.
Variables Units Coded variables level
a 1 0 1 a
X1 °C 39.55 60 90 120 140.45
X2 mol/l 0.0304 0.0515 0.0825 0.1135 0.1346
X3 min 16.36 30 50 70 83.64
Table 2 Experimental design matrix for the preparation of the styrene polymerization.
Run Coded factor Actual factor % Conversion
X1 X2 X3 X1 (°C) X2 (mol/l) X3 (min) Observed response Predicted response
1 0 0 0 90 0.0825 50 47.46 48.23
2 0 0 0 90 0.0825 50 48.12 48.23
3 1 1 1 60 0.0516 30 33.55 37.53
4 0 0 1.6818 90 0.0825 83.6359 48.34 50.53
5 0 0 0 90 0.0825 50 48.79 48.23
6 1 1 1 60 0.1135 30 45.92 48.44
7 0 1.68179 0 90 0.1346 50 57.84 58.40
8 1 1 1 60 0.1135 70 44.37 45.16
9 1 1 1 120 0.1135 30 76.82 76.41
10 1.6818 0 0 39.546 0.0825 50 45.25 40.59
11 1 1 1 60 0.0516 70 34.88 36.02
12 1 1 1 120 0.0516 70 54.31 52.53
13 0 0 0 90 0.0825 50 49.00 48.23
14 1 1 1 120 0.0516 30 55.19 55.14
15 1 1 1 120 0.1135 70 75.28 72.04
16 0 0 0 90 0.0825 50 47.24 48.23
17 0 0 0 90 0.0825 50 48.57 48.23
18 0 0 1.6818 90 0.0825 16.3641 58.72 55.48
19 0 1.6818 0 90 0.0304 50 34.44 32.83
20 1.6818 0 0 140.454 0.0825 50 74.39 78.00
Modelling and optimization of process variables 25
Figure 2b Response surface plot of the interactive effect of Figure 2c Response surface plot of the interactive effect of
initiator concentration and reaction time on % styrene conversion reaction temperature and reaction time on % styrene conversion
holding reaction temperature constant. holding initiator concentration constant.
Modelling and optimization of process variables 27
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