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Announcing the Emulsion Polymers Institute's 2012 Annual Short Course: "Advances in Emulsion Polymerization and Latex Technology"


This is a One-Week Short Course that will be offered by the Emulsion Polymers Institute (EPI) at Lehigh University in Bethlehem, Pennsylvania USA on June 11-15, 2012. Details of the course are given below.

 

Please note that there are no space limitations on the number of participants that can register and attend the course since the lectures are held in a large lecture hall.



COURSE ORGANIZER:

Dr. Mohamed S. El-Aasser
Professor, Department of Chemical Engineering
Vice President for International Affairs, Lehigh University
 

For more information, or to request a printed course brochure and registration form, please contact: 

Dr. Eric Daniels,  Emulsion Polymers Institute
E-Mail: Eric.Daniels@Lehigh.edu
Phone: (610) 758-3602; Fax: (610) 758-5880

Note: You may also download a registration form using the links given below to reserve your space in the 2012 Lehigh Short Course.

Credit cards (Visa, MasterCard or American Express ONLY) can be used to charge the course registration fee and University housing fees.

Click here to download a 2012 Short Course Registration Form in Word (Windows) format

Click here to download a 2012 Short Course Registration Form in Rich Text Format (RTF) (Windows) format

Click here to download a 2012 Short Course Registration Form in Adobe PDF format


COURSE DESIGN:

The course is an in-depth study of the synthesis, characterization, and properties of high polymer latexes. The subject matter includes a balance of theory and applications as well as a balance between chemical and physical problems. Lectures will be given by leading academic and industrial workers. Lectures will begin with introductory material and reviews, and will progress through recent research results.


LOCATION AND TIME:

Sinclair Laboratory Auditorium  
Lehigh University
7 Asa Drive
Bethlehem, Pennsylvania 18015

Lectures will start at 8:30 A.M.  Monday to Thursday.

Lectures on Friday will start at 8:00 A.M. and will end by 1:00 P.M.

All Lectures will be held in the Sinclair Laboratory Auditorium


 LECTURE/COURSE SCHEDULE FOR

2012 SHORT COURSE

 


MONDAY, JUNE 11, 2012

7:00 AM-8:15 AM Continental Breakfast To be determined
8:30 AM-10:00 AM Lecture 1 Kinetics of Free Radical-Initiated Polymerization (F. Joseph Schork)
10:00 AM-10:30 AM Coffee Break Sinclair Lab Auditorium Lobby (tentative)
10:30 AM-12:00 PM Lecture 2 Emulsion Polymerization Mechanisms and Kinetics  (Gary W. Poehlein)
12:00 PM-1:30 PM Lunch To be determined
1:30 PM-3:00 PM Lecture 3 The Role of Surfactants in Emulsion Polymerization Processes (Mohamed S. El-Aasser)
3:00 PM-3:30 PM   Coffee Break Sinclair Lab Auditorium Lobby (tentative)
3:30 PM-5:00 PM  Lecture 4 Semi-Continuous Emulsion Polymerization and Structured Latexes (Michael F. Cunningham)
7:00 PM-9:30 PM Mixer Campus Pizza

   

TUESDAY, JUNE 12, 2012  

7:00 AM-8:15 AM Continental Breakfast To be determined
8:30 AM-10:00 AM Lecture 5 Stabilization Mechanisms in Aqueous and Non-Aqueous Latexes  (Mohamed S. El-Aasser)  
10:00 AM-10:30 AM Coffee Break Sinclair Lab Auditorium Lobby (tentative)
10:30 AM-12:00 PM  Lecture 6 Sensors and Control of Emulsion Polymerization Reactors (F. Joseph Schork)  
12:00 PM-1:30 PM Lunch To be determined
1:30 PM-3:00 PM Lecture 7 Glass Transition Evolution of Plasticized Latex Films: An Important Process in the Application of Everyday Paints (James W. Taylor) 
3:00 PM-3:30 PM   Coffee Break Sinclair Lab Auditorium Lobby (tentative)
3:30 PM-5:00 PM  Lecture 8 Film Formation and Cohesive Strength Development from Latex Systems  (Andrew Klein)  
7:00 PM-8:30 PM Lecture 9: Question and Answer Session with Speakers Sinclair Lab Auditorium (tentative)

 

WEDNESDAY, JUNE 13, 2012

7:00 AM-8:15 AM Continental Breakfast To be determined
8:30 AM-10:00 AM Lecture 10 Advances in Miniemulsion Polymerization (Mohamed S. El-Aasser)  
10:00 AM-10:30 AM Coffee Break Sinclair Lab Auditorium Lobby (tentative)
10:30 AM-12:00 PM  Lecture 11 Engineering of Emulsion Polymerization Reactors  (Gary W. Poehlein)
12:00 PM-1:30 PM Lunch To be determined
1:30 PM-3:00 PM Lecture 12 Branching and Grafting in Emulsion Polymerizations (Peter Lovell)
3:00 PM-3:30 PM   Coffee Break Sinclair Lab Auditorium Lobby (tentative)
3:30 PM-5:00 PM  Lecture 13 Experimental Methods for the Characterization of Latex Particle Size and Particle Size Distribution (Cesar A. Silebi)   
5:15 PM-7:00 PM Mixer and No. 14- Evening Poster Session Iacocca Hall, Wood Dining Room, Mountaintop Campus
7:00 PM to 8:30 PM Banquet Wood Dining Room

 

THURSDAY JUNE 14, 2012

7:00 AM-8:15 AM Continental Breakfast To be determined
8:30 AM-10:00 AM Lecture 15 Living-Controlled Radical Polymerization in Bulk, Emulsion, and Miniemulsion (Michael F. Cunningham)  
10:00 AM-10:30 AM Coffee Break Sinclair Lab Auditorium Lobby (tentative)
10:30 AM-12:00 PM  Lecture 16 Latex Rheology (Cesar Silebi)
12:00 PM-1:30 PM Picnic Lunch Campus Square Courtyard
1:30 PM-3:00 PM Lecture 17 High Solids Latex Technology (Do Ik Lee)
3:00 PM-3:30 PM   Coffee Break Sinclair Lab Auditorium Lobby (tentative)
3:30 PM-5:00 PM  Lecture 18 Multi-Phase/Multi-Component Latex Particles (Peter Lovell)  

 

FRIDAY, JUNE 15, 2012

6:30 AM-7:45 AM Continental Breakfast To be determined
8:00 AM-9:30 AM Lecture 19 Water-Borne Pressure-Sensitive Adhesives (Peter Lovell) 
9:30 AM-9:45 AM Coffee Break Sinclair Lab Auditorium Lobby (tentative)
9:45 AM-11:15 AM  Lecture 20 Biopolymer-Based Nanoparticle Latexes for Industrial Applications: I. Development of New Starch-Based Nanoparticle Latex Binders for Paper Coating Applications
11:15 AM-11:30 AM Coffee Break Sinclair Lab Auditorium Lobby (tentaive)
11:30 AM-1:00 PM Lecture 21 Mixing Scale-Up in Emulsion Polymerization (Andrew Klein)


FEES

The fee structure for the 2012 course includes a variety of possible discounts as described below (note that discounts cannot be combined).  
       
 

Standard Course Tuition $ 1550
"Early Bird" Discount (prior to February 15, 2011) $ 1475
Multiple Participants Discount (2 or more participants from the same company) $ 1400 Each
EPI Industrial Liaison Member (1st approved participant free) $ 0
EPI Liaison Member- 2nd or Subsequent Participants $ 1225 Each
Graduate Student (needs approval) $ 775
1 Day Registration $ 700
2 Day Registration $ 1400

 

 Fees cover registration, a set of notes, five (5) days of continental breakfast, four (4) days luncheon, all breaks, a Pizza Party/Mixer on Monday evening, and a Banquet on Wednesday evening. Checks payable to Lehigh University/ Emulsion Polymers Course should accompany applications OR you may use the downloadable registration forms (links below) to e-mail or Fax your registration in. An invoice can then be sent to you OR you may use a credit card to pay for registration and University housing (Visa, MasterCard or American Express ONLY).  Please use the downloadable registration form if you would like to charge the course registration and University housing fees to a credit card. Refund requests received before April 16, 2012 will be honored in full. A processing charge of $650 will be deducted for cancellations after April 16, 2012.

Click here to download a 2012 Short Course Registration Form in Word (Windows) format

Click here to download a 2012 Short Course Registration Form in Rich Text Format (RTF) (Windows) format

Click here to download a 2012 Short Course Registration Form in Adobe PDF format


PARTICIPANTS

The course is designed for engineers and scientists who are actively involved in emulsion work as well as for those who wish to develop expertise in the area. A basic background in chemistry will be assumed. More advanced and experienced participants may elect to attend only those days in which material of specific interest is being presented. All participants will receive a printed set of course notes as well as a CD containing supplementary course materials in PDF format.


TRANSPORTATION AND LOCALE

Bethlehem is located in the heart of the Lehigh Valley about 50 miles north of Philadelphia and 80 miles west of New York City. It is easily accessible by plane via the Lehigh Valley International Airport (formerly known as the ABE, Allentown-Bethlehem-Easton Airport), by car via the east-west Route 78 (22) and the north-south Northeast Turnpike Extension (I-476) and Routes 309 and 378, or by bus from New York City (Port Authority Terminal). 


ACCOMMODATIONS:

Modern air-conditioned University dormitories are available within several blocks of the conference site.  Linens are provided. Single occupants will share a suite (living room and bathroom) with two (2) other course participants. Each person will have a private bedroom. Please see the following site for a description of the Campus Square dormitories:

http://www4.lehigh.edu/housing/residencehalls/az/campussquare.aspx

 A processing charge of one night will be deducted for housing cancellations after April 16, 2012.

A continental breakfast will be available to course participants at Brodhead House each morning. Lunches from Monday to Thursday are also included, as is a Pizza Party on Monday evening and a Banquet on Wednesday evening.

Hotels/motels are for the most part far from campus and will require transportation. Hotel/motel reservations should be made by contacting the hotel/motel directly.

* Only hotel within walking distance of the university.

             

ABSTRACTS OF COURSE LECTURES:


MONDAY, JUNE 11 2012

1. Kinetics of Free Radical-Initiated Polymerization--
F. Joseph Schork (Professor Emeritus, School of Chemical & Biomolecular Engineering, Georgia Institute of Technology )

        A review of the principles of free radical-initiated polymerization, including the four basic reactions of initiation, propagation, termination and transfer, inhibition, molecular weight and molecular weight distribution, effect of temperature and pressure, autoacceleration and diffusion control of termination and propagation, and copolymerization including copolymerization reactivity ratios and copolymer sequence distribution.


2. Emulsion Polymerization Mechanisms and Kinetics--
Gary W. Poehlein (Professor Emeritus of Chemical Engineering, Georgia Institute of Technology)

        Reaction mechanisms and kinetics of free radical polymerization will be reviewed. The unique features of emulsion polymerization will be outlined and the influence of the colloidal size of the reaction sites discussed. Kinetic theories due to Smith & Ewart, Stockmayer, O'Toole, Roe, Fitch, Ugelstad, and Gilbert will be discussed.

3. The Role of Surfactants in Emulsion Polymerization Processes--
Mohamed S. El-Aasser (Lehigh University)

        Surfactants play major roles during the particle nucleation and growth stages, with direct impact on latex particle size, size distribution, polymerization rate, molecular weight, and particle morphology. Surfactants are also essential during post-polymerization processes: stripping, storage, shipping, and formulation for several applications. The general characteristics of surfactants and their adsorption profiles on latex particles will be reviewed. The specific role of surfactants in determining the particle number according to the various nucleation mechanisms will be described. Three alternatives to conventional surfactants will be reviewed.
 

4. Semi-Continuous Emulsion Polymerization and Structured Latexes--
Michael F. Cunningham (Queen's University, Canada)

       Semi-continuous (or semi-batch) polymerizations in which the monomer is added incrementally during the course of reaction are commonly used in industrial processes because they allow control of the polymerization rate, and because they can be used to control the particle morphology. “Structured latexes” are emulsion polymer particles in which the internal morphology and/or composition vary through the particle. Examples include core-shell particles, and particles with radial composition gradients between the particle core and surface. The discussion will describe how semi-continuous processes are run, the unique features of operating an emulsion polymerization in semi-continuous mode, and how structured latexes can be synthesized.

 
TUESDAY, JUNE 12, 2012

5. Stabilization Mechanisms in Aqueous and Non-Aqueous Latexes--
Mohamed S. El-Aasser (Lehigh University)

      The basic concepts and terminology of colloid science will be introduced. The principles of electrostatic and steric stabilization mechanisms will then be reviewed. The inverse problem of coagulating and flocculating latexes will also be discussed.
 

6. Sensors and Control of Emulsion Polymerization Reactors--
F. Joseph Schork (
Professor Emeritus, School of Chemical & Biomolecular Engineering, Georgia Institute of Technology)

       
Recent developments in the area of on-line sensors, coupled with the availability of high-performance digital control systems, have opened up new opportunities for the efficient operation and control of latex reactors. Available sensors for on-line analysis will be discussed. The use of such measurements in the application of advanced control techniques to batch and continuous polymerization reactors will be reviewed, with special emphasis on controlling the undesirable process dynamics associated with continuous emulsion polymerization, and optimizing controllers for batch polymerization.


7. Glass Transition Evolution of Plasticized Latex Films: An Important Process in the Application of Everyday Latex Paints--
James W. Taylor (BASF Corporation) (co-author:
Dr. Timothy Klots, BASF)

        Water-borne latex paints are used in everyday life as decorative and as protective coatings.  The application of these paints is often taken for granted, but the drying process of latex paints involves the evaporation of water, solvents, and the coalescence of latex particles to a polymeric film that contains pigments, dispersants and surfactants. A model has been developed to better under the drying and coalescence of latex films.  The temporary plasticization of latex particles by filming aids and co-solvents is well known. A lowering of the glass-transition (Tg) below the cure temperature is necessary for the interdiffusion of polymer chains between particles. The Tg evolution with time of latex films plasticized with filming aids is modeled using fundamental equations.  Both the wet-stage and dry-stage are modeled.  Fundamental equations for the wet-film stage contain the evaporation rates, the distribution coefficients of solvents, and wet-stage activity coefficients.  The activity coefficients of the solvents during the wet-film evaporation are determined by measuring the minimum filming temperature of the plasticized latex film.  Solvent loss is also modeled during the subsequent dry-stage.  Activity coefficients of solvent loss from latex films can be determined either gravimetrically or by measuring the Tg evolution of the film as a function of time. The influence of temperature, humidity, and air-speed on drying is also incorporated.

The Tg evolution of latexes formulated with Butyl CARBITOL is studied in detail. During the dry-stage, the hardening of the film initially follows an evaporation controlled model for solvent loss, but then switches to a diffusion model as Tg of the film approaches ambient temperature. Although the Tg evolution of a latex film is complex, it will be shown that the initial Tg suppression produced by a solvent or solvents plays an important role in selecting the optimum solvent or solvent combination for corrosion resistance.

       
8. Film Formation and Cohesive Strength Development from Latex Systems--
Andrew Klein (Lehigh University)

      The cohesive properties of polymer films from latexes are dependent on the film formation mechanism. Polymer film formation from latex occurs either when: (a) the molecules from the individual polymer particles interdiffuse and entangle as the particle boundaries gradually disappear; or, when (b) the molecules partially interpenetrate and cross-link, forming interparticle "spotwelds"; or when (c) water-soluble molecules react or interact with functional groups on the particle surface. In the last two cases, the particle boundaries remain distinct. The role of interpenetration depth and the diffusion rate on cohesive strength development will be discussed, using model latex systems.
 

9. Evening Session: Question and Answer Session with Short Course Lecturers and Participants



WEDNESDAY, JUNE 13, 2012

10. Advances in Miniemulsion Polymerization--
Mohamed S. El-Aasser (Lehigh University)

      Despite the fact that the first miniemulsion polymerization was carried out at Lehigh University in 1972, the term "miniemulsion" was first coined only in 1981. The number of publications on miniemulsions has been increasing exponentially over the past decade, including a few patents.        

      Miniemulsions are relatively stable oil-in-water emulsions with average droplet diameters ranging from 50 to 500 nm. These are typically prepared using a mixture of a surfactant and a  low molecular weight, highly water-insoluble costabilizer (sometimes referred to as cosurfactant). In miniemulsion polymerization, the submicron monomer droplets are the main sites for particle nucleation and growth via free radical initiation using oil-soluble or water-soluble initiators. The stability behavior of miniemulsions has been explained theoretically based on the well know concepts of Ostwald ripening and thermodynamics. Miniemulsions have been exploited in making new types of polymer colloids (latexes) that were difficult and sometimes impossible to make using conventional emulsification or emulsion polymerization processes. These include preparation of artificial latexes and hybrid latexes, high solids latexes, polymerization of highly water-insoluble monomers and macromonomers, controlled polymer microstructure and morphology, encapsulation of pigments and dyes, and controlled molecular weight via living free radical polymerization. In this lecture both the theory and practice of miniemulsions will be discussed.
 

11. Engineering of Emulsion Polymerization Reactors--
Gary W. Poehlein (Professor Emeritus of Chemical Engineering, Georgia Institute of Technology)

      The various types of reactors: batch, semi-batch and continuous, used to produce synthetic latexes, will be reviewed. Pros and cons of various types of processes will be discussed and theoretical reactor models will be presented where appropriate. Reactor design and operating factors that influence product properties will also be reviewed.
 

12. Branching and Grafting in Emulsion Polymerizations --
Peter A. Lovell (University of Manchester, UK)

Branching in polymers produced by free-radical polymerization arises from chain transfer to polymer and has important effects on polymer properties. In emulsion polymerization, intermolecular chain transfer to polymer can lead to grafting of water-soluble polymers to latex particles, facilitating control of colloidal stability and latex rheology. Such branching and grafting is used to good effect in the emulsion polymer industry to control the end-use performance of latexes and emulsion polymers. This lecture will begin with an overview of the chemistry of branching and grafting. Case studies of branching in acrylate and vinyl acetate homopolymerizations and synergistic effects in copolymerization will then be presented , together with strategies for controlling the level of branching. This will provide the basis for considering grafting of water-soluble polymers used as colloid stabilizers in emulsion polymerizations. The chemical processes which the most commonly-used water-soluble polymers may undergo during emulsion polymerization will be illustrated through case studies that highlight the key principles for their control. 
 

13. Experimental Methods for the Characterization of Latex Particle Size and Particle Size Distribution --
Cesar A. Silebi (Lehigh University)

            The application of fractionation and non-fractionation methods for the determination of  particle size distribution, the range of applicability, and advantages and disadvantages and their on-line measurement capability will be discussed.  Among the methods examined are: classical and dynamic light scattering, sedimentation, disc centrifugation, electrozone sensing, sedimentation field flow fractionation, capillary hydrodynamic fractionation, and recent advances in hybrid methods of analysis.  Comparisons of several of these methods will be used to illustrate problems often encountered in the particle size distribution determination of latexes.  
 


14. Advanced Research Topics in Emulsion Polymerization and Latexes: An Evening Poster Session-- Graduate Students in the Emulsion Polymers Institute, Lehigh University.



THURSDAY, JUNE 14, 2012

 

15. Living-Controlled Radical Polymerization in Bulk, Emulsion, and Miniemulsion--
Michael F. Cunningham (Queen's University, Canada)

      “Living” (or “controlled”) radical polymerizations provide a novel and potentially inexpensive route to designing polymers with controlled microstructure (e.g. block copolymers, star polymers) and narrow molecular weight distributions. While extensive research has been conducted into homogeneous bulk and solution living radical polymerizations, investigations into aqueous dispersed phase systems (emulsion and miniemulsion polymerization) have only recently appeared. Although little progress has been realized with emulsion polymerization, considerable success has been achieved using miniemulsion polymerization with living radical systems. This presentation introduces the three major living radical polymerization chemistries (nitroxide-mediated radical polymerization (NMRP), atom transfer radical polymerization (ATRP) and reversible-addition-fragmentation-transfer polymerization (RAFT)), and summarizes recent progress of these systems in bulk, miniemulsion and emulsion.  The emphasis will be on heterogeneous systems, and more specifically on those aspects of operating in a heterogeneous environment that influence the polymerization rate, the molecular weight distribution and the livingness of the system.  


16. Latex Rheology--
Cesar A. Silebi (Lehigh University)

     Review of experimental studies illustrating the various factors that influence the rheological properties of latexes. Topics to be covered include the effects of solids concentration, particle size and distribution, electrolyte content, particle aggregation, adsorbed surfactants, non-spherical particle morphology, particle swelling, and the use of water-soluble associative and non-associative polymeric thickeners. Consideration will also be given to thickened latexes and variables affecting their rheological flow curves.


17. High Solids Latex Technology--
Do Ik Lee (Formerly with The Dow Chemical Company)

      High-solids latex technology is based on two basic principles: the maximization of latex particle packing and the minimization of the effective volumes of latex particles from the viewpoints of dispersion rheology. With these two principles at hand, the technology is concerned with the maximization of the volume solids of latexes, while meeting their respective end-use property requirements for a variety of applications. For this reason, although the technology is capable of achieving 70% or higher volume solids latexes, its objective is to increase the volume solids of the existing latexes by 5% to 15% by considering only a bimodal approach for the packing efficiency. This talk will describe the basic principles involved in the high-solids dispersion technology, and then discuss blending (i.e., large and small particle size latex blends) and in-situ (i.e., by either surfactant or seed addition during polymerization) methods of preparation for high-solids bimodal latexes.


18
. Multi-Phase/Multi-Component Latex Particles --
Peter A. Lovell (University of Manchester, UK)

     
Latex particles that comprise two or more phases/components are important both academically and industrially. They are used in a diverse range of applications, for example: toughening of plastics; adhesives; architectural coatings; inks; controlled-release of actives; and diagnostics.  This lecture will build upon the "Semi-Continuous Emulsion Polymerization and Structured Latexes" lecture by describing in greater detail the parameters which control the development of particle morphology when attempting to prepare, and control the morphology of, multi-phase latex particles in which there are two or more polymer phases. The importance of thermodynamic versus kinetic control will be emphasized and strategies for achieving control of morphology will be described together with their limitations. Some examples will be given to illustrate the principles. The focus will then switch to preparation of multi-component latex particles in which there are both polymeric and non-polymeric materials present. Different approaches to preparation of multi-component latex particles will be described through examples of encapsulating non-polymeric materials, templating of particle morphology, and synthesis of surface-functionalized particles.

 

FRIDAY, JUNE 15, 2012


19. Water-Borne Pressure-Sensitive Adhesives-- Peter A. Lovell (University of Manchester, UK)

    Pressure sensitive adhesives (PSAs) are viscoelastic materials which adhere to substrates on the application of slight pressure over short periods of time. They are ubiquitous in everyday life as self-adhesive tapes and labels used in a wide variety of applications (e.g., bonding, signing and marking, healthcare, automotive, electronics, furniture, security, food packaging and retailing). Over the past few decades, water-borne PSAs based on latexes prepared by emulsion polymerization have gained market share at the expense of flammable, environmentally-unfriendly solvent-borne PSAs and now comprise the largest proportion of the overall PSA market. The growth has arisen not only because they replace solvents with water, but also because the latexes have low viscosity at high solids contents which brings benefits in formulation, handling, transport and coating.  This lecture will describe the different types of PSAs before focusing on the principle components used in preparation of acrylic water-borne PSAs and their roles in controlling latex properties and adhesive performance. Effects of latex particle composition/morphology, polymer properties and branching on the performance of PSA films will be discussed. A case study will presented to demonstrate principles for control of adhesive performance through careful design of structured latex particles that determine the sub-micron and nanoscale morphology of PSA films as a consequence of the mechanism of film formation from latexes.


20. Biopolymer-Based Nanoparticle Latexes for Industrial Applications: I. Development of New Starch-Based Nanoparticle Latex Binders for Paper Coatings Applications -- Do Ik Lee (Formerly with The Dow Chemical Company) (Co-Authors: Steven Bloembergen, EcoSynthetix Inc., Michigan, Ian J. McLennan and John van Leeuwen, EcoSynthetix Inc., Ontario, Canada)
     

       Biobased latex binders adopted in the paper industry in 2008 were the first use of biopolymer-based microgels and nanogels for large-scale industrial applications [1-12], although they had been explored and used for drug delivery and other bio-medical applications for a long time [13].  Both biobased latex binders and biopolymer-based microgels and nanogels can be broadly classified as a special type of latexes whose particles are made up of water-swollen crosslinked hydrophilic polymers.  Since the biobased latex binders currently used in the paper industry are water-swollen crosslinked starch nanoparticles, their wet and dry properties depend mainly on their particle size and crosslink density.  The crosslink density of starch molecules forming the nanoparticles is especially important because it controls the extent of water swelling (swell ratio) [3,4], that is, as the crosslink density increases, the swell ratio of crosslinked starch nanoparticles decreases.  Varying swell ratios of the water-swollen starch nanoparticles not only set them apart from conventional starches and synthetic latexes in their rheological behavior, but also differentiate themselves in paper coating performance.  Their unique rheological behavior and paper coating performance will be discussed based on theoretical considerations as well as some laboratory testing, pilot coater and mill trial results.

       Starch-based biopolymer nanoparticle latexes were developed in the early 2000s for industrial applications by two patented processes: Continuous Reactive Extrusion Process [14] and Inverse Emulsion Process [15].  The current biobased latex binders are manufactured by a continuous  reactive extrusion process comprising of solubilizing starch granules, i.e. converting the very high-solids starch paste into a thermoplastic melt phase, and then crosslinking and sizing the solubilized starch molecules into nanoparticles [14].  The resulting product from the extruder is nearly dry agglomerates of crosslinked starch nanoparticles which are subsequently pulverized as a final powder product.  This process was thought to be a good way to disperse TiO2 particles uniformly and associate them with starch nanoparticles.  This is how we have developed a new brightness grade of biobased latex binders.  The performance of this new biobased latex binder grade will be discussed in terms of the brightness and opacity of paper coatings [8, 11-12].

       The current biobased latex binders are cured by using glyoxal-type curing agents (starch insolubilizers) to improve their wet strength in coated paper and paperboard applications.  Although such curing agents have been found to be adequate up to about 35% replacement of synthetic latexes for paper coatings, it was thought that polymeric curing agents could be more effective for particulate binders such as our biobased latex binders that consist of crosslinked biopolymer nanoparticles.  Preliminary results will be discussed in terms of the substitution levels of synthetic latexes in base and top coatings as well as in single coatings [11].

       Finally, the reduction in carbon footprint and green house gas emissions that results from the use of biobased latex binders will be discussed by comparing starch-based latex binders with petroleum-based synthetic latex binders [8, 11, 16-18].

 REFERENCES

  1.  van Leeuwen, J., “Paper Coating - SBR Latex Replacement Technology”, 2006 TAPPI Coating and Graphic Arts Conference, Atlanta, GA., April 2006.

  2. Klass, C. P., “New Nanoparticle Latex offers Natural Advantage”, Paper360°Magazine, p. 30-31, January 2007.

  3. van Leeuwen, J., “Update on Biopolymer Nanoparticle Latex Development and Applications”, 2007 TAPPI Coating and Graphic Arts Conference, Miami, FL., April 22-25, 2007.

  4. Bloembergen, S., McLennan, I., Lee, D. I., and van Leeuwen, J., “Paper Binder Performance with Nanoparticle Biolatex™: EcoSynthetix develops EcoSphere® biolatex for replacement of petroleum based latex binders”, ACFS, Montreal, June 11-13, 2008.

  5. Bloembergen, S., McLennan, I. J., Lee, D. I., and van Leeuwen, J., “Paper binder performance with biobased nanoparticles. A starch-based biolatex can replace petroleum-based latex binders in papermaking”, Paper360ºMagazine, 46-48, Sept. 2008.
  6. Figliolino, F.C., Rosso, F., van Leeuwen, J. and Klass, C.P., “Mill Experiences with Biolatex in Brazil”, 2009 TAPPI PaperCon Proceedings, Section 19-1, 2009.
  7. Figliolino, F.C. and Rosso, F., “Reducing Carbon Footprint with Biolatex”, Paper360ºMagazine, 25-28, Aug. 2009.
  8. Bloembergen, S., VanEgdom, E., Wildi, R., McLennan, I.J., Lee, D.I. Klass, C.P., and van Leeuwen, J., "Biolatex Binders for Paper and Paperboard Applications", presented at 7th International Paper and Coating Chemistry Symposium, McMaster, June 2009; Accepted for publication in Journal of Pulp and Paper Science (JPPS) on Nov. 26, 2010 to appear in Volume 36, No 3-4, 2011.

  9. Bloembergen, S., VanEgdom, E., Wildi, R.,  McLennan, I. J., Lee, D.I., Klass, C. P. and van Leeuwen, J., "New Biolatex Binders Based on Biopolymer Nanoparticles" presented by D. I. Lee, 2009 PTS Nanotechnology Seminar in Munich, Germany, April 21-22, 2009.

  10. Lee, D. I., Bloembergen, S., and van Leeuwen, J., “Starch-Based Biopolymer Nanoparticle Latexes for Industrial Applications,” The 3rd Asian Symposium on Emulsion Polymerization and Functional Polymeric Microspheres, September 20-23, 2009, Jeju Grand Hotel, Jeju, South Korea.

  11. Lee, D. I., Bloembergen, S., and van Leeuwen, J., “Development of New Biobased Emulsion Binders,” Presented at PaperCon 2010, “Talent, Technology and Transformation,” Atlanta, GA, May 2-5, 2010.

  12. 12.  Lee, D. I., Bloembergen, S., McLennan, I. J., and van Leeuwen, S., “Biopolymer-Based Nanoparticle Latexes for Industrial Applications: I. Development of New Starch-Based Nanoparticle Latex Binders for Paper Coating Applications”, Chapter 1 in a book (in press) entitled “Emulsion Polymerization and Functional Polymeric Microspheres – Science and Technology” based on “The 3rd Asian Symposium on Emulsion Polymerization and Functional Polymeric Microspheres (ASEPFPM)” held in September 20-23, 2009, Jeju Grand Hotel, Jeju, South Korea.

  13. Oh, J. K., Lee, D. I., and Park, J. M., “Biopolymer-based microgels/nanogels for drug delivery applications”, Progress in Polymer Science 34, 1261–1282, 2009.

  14. Giezen, F., Jongboom, R. O. J., Feil, H., Gotlieb, R .O. F. and Boersma, A., “Biopolymer Nanoparticles”, U.S. Patent 6,677,386, 2004; Wildi, R. H., VanEgdom, E., and Bloembergen, S., “Process for Producing Biopolymer Nanoparticles”, U.S. Patent Application 60/837,669, 2006.
  15. Van Soest, J. J. G., Stappers, F. H. M., Van Schijndel, R. J. G., Gottlieb, K. F., and Feil, H., “Method for the preparation of starch particles,” US Patent No. 6,755,915, June 29, 2004.
  16. Narayan, R. “Biobased and Biodegradable Materials, Rationale, Drivers, & Technology Exemplars”, ACS (An American Chemical Society Publication) Symposium Ser 939,  Ch. 18, pg 282, 2006.
  17. Narayan, R. “The Promise of Biobased and Biodegradable Polymer Materials in Paper & Paperboard Products - Reducing Carbon Footprint and Improving Environmental Performance”TAPPI (Technical association of the Pulp & Paper Industry) Conference Proceedings PaperCon09, 2009.
  18. International Standards Organization, ISO 14064-2:2006, Greenhouse Gases - Part 2: Specification with guidance at the project level for quantification, monitoring and reporting of greenhouse gas emission reductions or removal enhancements.

 

21. Mixing Scale-Up in Emulsion Polymerization--
Andrew Klein (Lehigh University)

      Scale-up of the mixing process in emulsion polymerization involves breaking the process down into individual but interrelated steps. The effect of mixing on the microscopic heterogeneity of the continuous phase, fluid shear rates and heat transfer allows each to be considered separately. A few of these effects will be discussed and illustrated with specific examples. The utility of bench scale experimentation, using an impeller-modified reaction calorimeter (Mettler RC1), with a view toward scale-up with some early experimental results, will also be discussed.

 

LECTURERS:


Michael F. Cunningham--
Associate Professor within the Department of Chemical Engineering, Queen’s University, Kingston, Ontario, Canada.  He received his Ph.D. in 1990 from the University of Waterloo where he studied chemical engineering with Prof. K.F. O’Driscoll. Prior to his joining Queen’s University, he was with the Xerox Research Centre of Canada for six years.  While there he conducted research into the design of composite polymer particles.  He was co-inventor of a novel composite particle that is now a critical component of the xerographic developer in Xerox copiers and printers. This work has led to 25 U.S. patents.  Among his research interests are the areas of polymer reaction engineering, emulsion/miniemulsion polymerization, and living radical polymerization. 


Mohamed S. El-Aasser--Vice President for International Affairs, Lehigh University, and formerly Provost, Lehigh University; Professor of Chemical Engineering. Ph.D. from McGill University and Pulp and Paper Research Institute in 1972. Research interests include emulsion polymerization, emulsification, surface and colloidal properties of latexes, latex film formation, adsorption from solutions, and stabilization of colloids.

Andrew Klein-- Professor of Chemical Engineering, Lehigh University. Ph.D. in Chemical Engineering from North Carolina State University at Raleigh. Industrial experience in emulsion polymers with GAF and National Starch and Chemical Company. Research interests include colloid and surface chemical aspects of heterogeneous polymerization kinetics, related thermodynamics, engineering and applications.

Do Ik Lee-- B. S. degree in Chemical Engineering from Seoul National University in 1959 and both M. S. and doctoral degrees in Chemical Engineering from Columbia University in 1964 and 1967, respectively. Currently, Adjunct Professor in the Department of Paper and Printing Science Engineering at Western Michigan University and a TAPPI Fellow.  Formerly, Senior Scientist in Emulsion Polymers R&D at The Dow Chemical Company for 35 years. His research interests are latex technology, emulsion polymerization, structured latex polymerization, controlled free-radical emulsion polymerization, solid and hollow plastic pigments, paper coating technology, paper chemistry, colloid science, particle packing, dispersion rheology, and associative alkali-soluble latexes. He holds 28 U.S. patents.

Peter A. Lovell--Professor of Polymer Science in the School of Materials at The University of Manchester in the United Kingdom. He was founding Chairman of the UK Polymer Colloids Forum, which was established in 1993, and was Chairman of Macro Group UK from 2004-2007. His research focuses mainly around aspects of emulsion polymerization and related processes.  Prominent in this research has been synthesis of core-shell and multi-layer particles (for applications in toughening plastics and as soft adhesives) and studies of the chemistry (and extent) of branching and grafting, including grafting to water-soluble polymeric colloid stabilizers. Recent research includes a novel chemistry for room-temperature crosslinking during latex film formation, synthesis of new nitroxides for use in controlled miniemulsion polymerization, development of click chemistry for latex particle functionalization and the lead role in a European collaborative research programme for development of high-performance water-borne pressure-sensitive adhesives.

Gary W. Poehlein-- Professor Emeritus of Chemical Engineering, Georgia Institute of Technology. Ph.D. in Chemical Engineering from Purdue University. Industrial experience with the Procter and Gamble Company. Research interests include kinetics of emulsion polymerization and continuous reactor systems.

F. Joseph Schork-- Professor and Chair, Department of Chemical and Biomolecular Engineering, University of Maryland.  Ph.D. in Chemical Engineering from the University of Wisconsin working in the field of emulsion polymerization reactor dynamics. Industrial experience with E.I. DuPont de Nemours & Company in the areas of emulsion polymerization and digital process control. Research interests in polymerization reaction engineering, digital control of polymerization reactors, system dynamics and nonlinear control. Consultant to various companies in the area of polymerization reaction engineering.

Cesar A. Silebi-- Professor of Chemical Engineering at Lehigh University. Ph.D. from Lehigh University. Research interests include particle separation processes, rheological and colloidal properties of latexes, multi-component transport in emulsions, and stability of colloidal systems.

James W. Taylor--received his Ph.D. Degree in Chemistry from the University of Tennessee in 1982, after which he joined Union Carbide Corporation.  He was appointed principal Scientist 2011 and currently serves as the senior research scientist in the Emulsion Research group for BASF located in Wyandotte, MI.  Dr. Taylor’s current interests include crosslinking technology, emulsion design, and film formation.


List of companies/Universities who have participated in the short course over the past 5 years

Arkema Inc Ashland Inc.
Asian Paints  
Avery Dennison Baker Petrolite
Bangkok Synthetics Bangs Labs
Barrday Inc. BASF Corporation
Benjamin Moore & Co. Bioarray Solutions
Casco Adhesives AB Celanese
Centro de Inestigacion en Polimeros Cheil Industries
Chemicals Research Institute Cognis Corporation
Colorquimica SA Commercial Mexicana de Pinturas SA
ConocoPhillips Corporacion Peruana de Productos Quimicos
Cytec CoatingSys
Coopervision Inv.  
Dai-Ichi Kogyo Seiyaku Dade Behring
Dai Nippon Toryo Co. Denver Resins
DOW Chemical Dow Reichold Specialty Latex
DuPont Dynalene Heat Transfer
Emerald Performance Materials Essential Industries
454 Life Sciences Formosa Plastics Corp.
Franklin International Gelie Co. Ltd.
General Electric Co. Gorilla Glue Co.
Grain Processing Corp. H.B. Fuller
Hanwha Chemical Hansol Chemical
Henkel Hercules
Hewlett Packard Co. Hexion Specialty Chemicals
Isolatek International James Hardie Building Products
Kemtec E. Kerwin Kolinek Consulting
Kumho Petrochemical Lanxess
LG Chemical Ltd. Lexmark International
Lintec Corp. Lubrizol Corp
Luminex Corp. Mapei
Mica Corporation  
3M Momentive Specialty Chemicals
NanoMR  
NASA Nipsea Technologies
Nitto Denko Japan Noveon
Omnova Solutions Pegatex
Pidilite Industries  
PPG Industries Queen's University
Reichold Inc. Rhodia
Samsung  
Renner Sayerlack Rohm and Haas Co.
Samsung Cheil Samsung Fine Chemicals
Sealy Seradyn Inc.
Siemen's Healthcare Diagnostics Solucor
Stanchem Inc. Starquim
Teknoquimica SA ThermoFisher Scientific
University of Hamburg University of Maryland
University of Toronto The Valvoline Co.
Wacker Polymer Systems Xerox Corporation
Yonsei University Zeon Chemicals
   
 



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