THEORY-BASED IMPROVEMENTS OF CONTINUOUS POLYMER FRACTIONATION DEMONSTRATED FOR POLY(CARBONATE)

For the first time, a quantitative theoretical analysis (liquid / liquid phase equilibria treated by means of the continuous thermodynamics) of the operating characteristics of continuous polymer fractionation (CPF) was performed. The results of these calculations were compared with data published for CPF of polyethylene. It turned out that the efficiency of the conventional CPF corresponds to approximately two theoretical plates only. For this reason, several improvements, suggested by theoretical considerations, were realized experimentally, for which purpose the system dichloromethane/diethylene glycol/bisphenol-A polycarbonate was chosen. The pulsating sieve-bottom column was replaced by a nonpulsating column filled with glass beads. In this manner, the number of theoretical plates could be raised considerably. A further improvement of the fractionation efficiency results from the reflux of part of the polymer contained in the sol phase. In praxi, this situation was realized by putting a condensor on top of the column and introducing the feed somewhere near its upper third. After predictive calculations and orienting experiments, 125 g of a polycarbonate with M(w) = 29 kg/mol and a nonuniformity U = 1.3 were fractionated in four consecutive CPF runs (where the gels were directly used as feed for the next step) into five fractions of approximately equal weight. Except for the lowest-molecular-weight fraction, one obtains nonuniformities on the order of 0.1.