AQUEOUS SUSPENSIONS OF ORGANIC PEROXIDES

Abstract: Novel process for the preparation of a stable, pumpable aqueous suspension of an organic peroxide or mixed organic peroxides, and also novel suspension itself. Such suspensions are suitable for the initiation of polymerisation/ copolymerisation of ethylenically unsaturated monomers in particular vinyl chloride, to form respectively general purpose polymers and polyvinyl chloride that meets the volume resistivity specifications required of electrical cable sheathing materials. The said process is characterised in that the aqueous suspension is made to contain one or more organic peroxides, at least one protective colloid and a surfactant (as herein defined) selected from the group consisting of fatty acid esters of polyhydric alcohols, and alkanolamides.

Description: AQUEOUS SUSPENSIONS OF ORGANIC PEROXIDES Technical Field of the Invention The invention relates to aqueous suspensions of orga peroxides and to a process for their preparation. This invention is directed to a novel process for the preparation of a stable, pumpable, aqueous suspension of an organic peroxide or mixed organic peroxides, and also to the novel suspension itself. This suspension is especially suitable for the initiation of polymerisation of vinyl chloride to form polyvinyl chloride that meets the volume resistivity specifications required of electrical cable sheathing materials. It is also suitable for the polymerisation/copolymerisation of ethylenically unsaturated monomers to form general purpose polymers. Of all the possible homo- and co-polymerisation reactions of ethylenically unsaturated monomers, an important one, commercially, is the suspension polymerisation of vinyl chloride. The vinyl chloride monomer is dispersed in water in a • reactor, and polymerisation initiation is effected per medium of a thermally labile compound capable of generating free radicals - such " as peroxydicarbonates and aromatic/aliphatic diacyl peroxides. Since these organic peroxides are solids at temperatures of about 20°C, feeding initiator into the reactor can present problems to polymer manufacturers. The exacting specification of volume resistivity, for electrical grade polyvinyl chloride, has put a further burden on manufacturers. The specification as laid down in the National Standards is for "finished" polymer i.e. polyvinyl chlorine resin that has been compounded with plasticiser such as di-isoocyl phthalate, and stabilisers such as a basic lead stearate or stearic acid. In practice, the actual "buying" specifications of cable manufacturers, for polyvinyl chloride resin, are generally ten times higher than the minimum National Standards as regards volume resistivity, to allow for trace impurities in the compounding additives degrading the inherent resistivity of the resin. From our experience it is known that, prior to the present invention, the best way to produce this electrical grade resin by suspension polymerisation was to use technically pure organic peroxide, choosing either a liquid or a powder or flake. In those instances where the organic peroxide (usually a peroxydi-carbonate, an aliphatic diacyl peroxide or an aromatic diacyl peroxide) was a powder or flake, it may additionally have been water damped for safety reasons. One method of charging initiator into the reactor has been to open a port in the reactor after the vinyl chloride monomer is thoroughly dispersed in the water and to add, manually or mechanically, an appropriate quantity of pure or dispersed initiator. However, this practice is generally no longer feasible since many countries have acted, by legislation, to regulate the escape into the air of monomers detrimental to health, e.g. vinyl chloride. Reactor trains are often now fully closed and, therefore, initiator additions must be via some form of pump or syringe, thereby requiring the organic peroxide to be in a fluid, pumpable form at ambient ' temperatures, e.g. up to about 35°C. Pure short chain length alkyl peroxydicarbonates, or peresters can be liquid at ambient temperatures. However, the former are explosively unstable at such temperatures, whilst the latter give unacceptable performance in the polymerisation reactor. Simple dissolution of the organic peroxide - in an organic solvent such as benzene, chloroform or acetone - is impractical since the decomposition rate of the organic peroxide is markedly increased. As well as rapid peroxide loss, the exotherm of decomposition may give rise to spontaneous ignition or explosion. We are thus left with dispersion/emulsifying/suspension of the organic peroxide into water as representing the best mode of fl idising an initiator system, especially if the organic peroxide is solid at a temperature of about 20°C. Our investigations have not revealed any prior art directed to the production of, or capable of producing, a dispersion of initiator (s) that is suitaole for the manufacture of electrical grade polyvinyl chloride. Whilst there have been a number of proposals aimed at producing dispersions of organic peroxides that are alleged to be suitable for the polymerisation of ethylenically unsaturated monomers (including vinyl chloride) , all fall short of the requirements and capabilities of the present invention. In summary, our findings indicate that all prior art techniques for making aqueous dispersions of organic peroxides that are solid at about 20°C have been unable to produce electrical grade polyvinyl chloride resin, and/or have done little more than produce milled initiator slurried into water at the point of use with concomitant lack of physical stability and homogeneity. In contradistinction to the above, the present invention is predicted upon our discovery that an aqueous suspension or, dispersion (these terms, in this specification, have the same meaning and may be used interchangeably) of an " organic peroxide, or of mixed organic peroxides, that is especially suitable for the production of electrical grade polyvinyl chloride can in fact be made. Accordingly, in one broad aspect, there is provided by the invention a process for the production of a stable, pumpable, aqueous suspension of an organic peroxide or of mixed organic peroxides, which suspension is especially suitable for the polymerisation of vinyl chloride monomer to form a polyvinyl chloride meeting the specifications required of electrical cable sheathing materials and is also suitable for the polymerisation/ co-polymerisation of ethylenically unsaturated monomers to form general purpose polymers, the said process being characterised in that the aqueous suspension is made to contain one or more organic peroxides, at least one protective colloid and a surfactant (as herein defined) selected from the group consisting of fatty acid esters of polyhydric alcohols, and alkanolamides. The invention also includes within its ambit a stable, pu pable, aqueous suspension of an organic peroxide or of mixed organic peroxides, having the properties indicated above, both per se and as made in accordance with the process of the invention. The said suspension comprises one or more of said organic peroxides, at least one protective colloid and a surfactant (as herein defined) selected from the group consisting of fatty acid esters of polyhydric alcohols, and alkanolamides. The invention will now be described with sequential reference to (i) preferred sub-generic features, and (ii) numerical examples. However, as a prelude thereto, we now set forth definitions of certain terms employed both heretofore and in the ensuing description. The criterion "stable"' is taken to mean - with respect to a prescribed (e.g. four month) holding period at ambient temperature (about 20°C) since manufacture - the physical stability " of an aqueous suspension per se (indicated by a maximum of 10% v/v of clear water substrate separated from the otherwise homogeneous suspension) ; the chemical stability of the organic peroxide(s) (as measured by a maximum loss of 5% of active peroxide relative to the initial organic peroxide content) ; and the stability of the viscosity of the suspension (i.e. less than 20% variation relative to the initial viscosity) . "Pumpable", as a property of the suspension, is taken to mean that the homogenised suspension has a viscosity of less than 500 poise and prefereably of less than 100 poise when measured with a Brookfields RVF viscometer using a #3 spindle at 4 r.p. . Volume resistivity specifications - as required of polymers to be used for insulation and sheathing of electrical cable - are contained in the appropriate National Standards. For example, in Australia the standards AS 3147 and AS 3191 specify the minimum resistivity of cable grade PVC as 35.7 gigaohm rr.etre at 20°C and the method of measurement is specified in AS 1255.1 - 1973. The generic term "ethylenically unsaturated monomers" includes vinyl halides such as vinyl chloride, vinyl bromide and vinyl fluoride; vinylidene halides such as vinylidene chloride and vinylidene fluoride, or other molecules containing a terminal CH2 = C d group such as ethylene, propylene, vinyl acetate. The surfactant of the novel suspension and process - selected from the esters and alkanolamides indicated above - is defined as a component (i) which is capable of fulfilling its function as a single such component and (ii) which, in the case of the fatty acid ester ' s of polyhydric alcohols, excludes ethoxylated, and functionally equivalent, derivatives of such esters. Ethoxylated .(and other inhibitory) derivatives of fatty acid esters of polyhydric alcohols are excluded because (inter alia) suspensions ' , incorporating such derivatives as surfactants, do not possess the required stability, and are incapable of producing electrical grade polyvinyl chloride resin (in short, such suspensions suffer from the disadvantages of prior art techniques as summarised above) . Whilst the expression "a surfactant" is not intended to exclude the presence and employment of more than one such component (i.e. the use of two or more such components would not be outside the broad scope of the invention) , the invention is principally directed to the utilisation of the capability indicated in point (i) immediately heretofore i.e. the surfactant component is usually a single such fatty acid ester or alkanolamide. Turning now to preferred sub-generic features, the organic peroxide(s) is (are) solid at about 20°C with a total final concentration, in the aqueous suspension, of from 5 to 50% by weight (even more preferably 10 to 50% by weight) . The organic peroxides are desirably selected from the following: 1. Peroxydicarbonates - such as di yristyl peroxydi- carbonate, dicetyl peroxydicarbonate, distearyl peroxydi- carbonate, bis (4-tert-butylcyσlohexyl) perόxydi- carbonate, bis (4-tert-amylcyclohexyl) peroxydicarbonate, dicyσlohexyl peroxydicarbonate and dibenzyl peroxydi¬ carbonate. 2. Aliphatic diacyl peroxides - such as dilauroyl peroxide, dimyristoyl peroxide, didecanoyl peroxide. 3. Aromatic diacyl peroxides - such as dibenzoyl peroxide, bis (2,4 . dichlorobenzoyl) peroxide, bis (o-methoxy-benzoyl) peroxide. Preferred protective colloids include water soluble polymers of the cellulose derivatives class such as hydroxypropyl cellulose, hydroxypropyl methyl cellulose, hydroxyethyl cellulose, methyl cellulose, carboxymethyl cellulose; natural products such as gelatine, starch; and suspending agents used to disperse vinyl chloride monomer in water (in a reactor) such as polyvinyl alcohol, polyvinyl acetate and polyvinyl pyrrolidone. The addition rate of the colloid component may be from 0.1 to 10% by weight but, even more preferably, from 0.5 to 5% by weight. Hydroxylated alkyl celluloses also ' give slightly better long term physical stability of the finished suspension and are preferred. If desired, more than one colloid may be employed. The surfactant is exemplified by fatty acid esters of polyhydric alcohols such as glycerol monostearate, glycerol monooleate, glycerol monopalmitate, sorbitan monolaurate, sorbitan monooleate, sorbitan sesquioleate, sorbitan monopalmitate, glycerol dilaurate, glycerol dioleate, glycerol distearate, and glycerol sesquioleate. As alkanolamide, there may be employed diethanolamide coconut oil or glycerol diethanolamide. The surfactant may desirably be incorporated at between 0.1 to 5% by weight, more preferably 0.25 to 2% by weight. As indicated heretofore, a single surfactant is adequate to achieve our purpose. When water, organic peroxide(s), protective colloid and surfactant as set forth above are stirred in together and dispersed using appropriate homogenising equipment, a pumpable aqueous suspension of the organic peroxide is produced which will be successful in initiating vinyl chloride polymerisation to yield resin of electrical cable sheathing grade. The suspension will also naturally initiate production of polyvinyl chloride resin of less stringent specification. Among further properties of this pumpable aqueous dispersion of organic peroxide(s) that make it superior to prior art dispersions may also be listed the following: its chemical, rheological and physical stability (e.g. over at least a four months holding period at ambient temperatures at about 20°C) ; Its ready reincorporation of any water that might separate (since the surfactant ensures that any organic matter will float and not cake) ; reincorporation by simple shaking (of the container holding the suspension) will reform the suspension to almost the same physical stability as before separation occurred; its ready dilutability to lower strength dispersions by adding the stock dispersion to water with appropriate ho ogenisation. The invention will now be further described with reference to the previously foreshadowed numerical examples - which amply demonstrate the dispersion into water, of an organic peroxide solid at about 20°C, using only a protective colloid and a surfactant as herein defined. Again, it is to be understood that these examples are merely typically illustrative of the invention, and are therefore in no way to be limitatively construed. For instance, such criteria as the order of addition of the ingredients is generally not critical. In this connection however, it is mentioned that, from a plant production point of view the organic peroxide dispersion can be achieved in the shortest time oy initially charging the make up vessel with water followed, sequentially, by addition of the organic peroxide(s) , the surfactant, and finally the protective colloid. The suspension polymerisation of vinyl chloride, using as initiator the so produced suspension, is carried out in conventional fashion. EXAMPLE 1 To a stirred mixture of 775 g of water and 200 g of dicetyl peroxydicarbonate was added 5 g of glycerol monostearate powder followed by 20 g of hydroxypropyl methyl cellulose. After stirring for 15 minutes the mixture was passed through a colloid mill once. The smooth free flowing homogenous dispersion had a viscosity of 70 poise. Analysis by iodimetry gave a diσetyl peroxydicarbonate concentration of 19.9% by weight. After four months standing at 23°C in diffuse natural light the viscosity was ' 65 poise, the peroxydicarbonate was 19. ' 6% by weight and 52 mis of water was tapped off from the bottom of the container. Re-adding the water to the container and shaking by hand for 30 seconds produced a homogenous dispersion again. Tnis showed no separation after one months standing. Polyvinyl chloride hides made from resin incorporating this initiator and formulated with common ingredients for cable sheathing gave a volume resistivity of 1.2 x 10 14 ohm. ' cm at 20°C. Dilution of 100 is of this 20% dispersion with 300 is of demineralised water and homogenisation using appropriate equipment gave a suspension which showed no separation of substrate water after 2 days standing. After a fortnight's standing 50% by volume of water had separated. On shaking the container by hand for 30 seconds reincorporation of the water was effected. This restored suspension maintained its integrity over 4 hours standing. EXAMPLE 2 To a stirred mixture of 775 g of water and 200 g of bis (4-tert-butylcyclohexyl) peroxydicarbonate was added hydroxyethyl cellulose. After stirring for 15 minutes the mixture was passed through a colloid mill once. The resulting smooth free flowing homogenous dispersion had a viscosity of 120 poise. Analysis by iodimetry gave a concentration of the bis (4-tert-butylσyclohexyl) peroxy-diσarbonate of 19.6% by weight. After four months standing at 23°C in diffuse natural light the viscosity was 100 poise, the peroxydicarbonate concentration was 19.2% by weight and 45 mis of water was tapped off from the bottom of the container. Re-adding the water to the container and shaking by hand for 30 seconds produced a homogenous dispersion again. After a further months standing 15 mis of water were tapped from the bottom. - Polyvinyl chloride hides made from resin incorporating this initiator, and formulated with common ingredients for cable sheathing, gave a volume resistivity of 1.4 x 10 14 ohm. cm at 20°C. Dilution of 100 mis of this 20% dispersion with 300 mis of demineralised water and homogenisation using appropriate equipment gave a suspension which showed no separation of substrate water after 2 days standing. After a fortnights standing 50% by volume of water had separated. On shaking the container by hand for 30 seconds reincorporation of the water was effected. This restored suspension maintained its integrity over 4 hours standing. EXAMPLE 3 To a stirred mixture of 660 g of water -and 300 g of dimyristyl peroxydicarbonate was added 10 g of dietnanolamided coconut oil followed by 30 g of hydroxypropyl methyl cellulose. After stirring for 15 minutes the mixture was passed through a colloid mill once. The resulting smooth free flowing homogenous dispersion had a viscosity of 95 poise. Analysis by iodimetry gave a concentration of the dimyristyl peroxydicarbonate of 29.8% by weight. After four months standing the viscosity was 105 poise, the peroxydicarbonate concentration was 29.5% by weight, and 65 mis of water was tapped . from the bottom of the container. Re-adding the water to the container and shaking by hand for 30 " seconds produced a homogenous dispersion from which only 20 mis of water was tapped after a further months standing. EXAMPLE 4 To a stirred mixture of 800 g of water and 150 g of bis(4-tert-butylcyclohexyl) peroxydicarbonate was added 10 g of sorbitan sesquioleate followed by 40 g of polyvinyl alcohol. After stirring for 15 minutes the mixture was passed through a colloid mill once. The resulting smooth free flowing homogenous dispersion had a viscosity of 55 poise. Analysis by iodimetry ga,ve a concentration of the peroxydicarbonate of 15.0% by weight. After four months standing the viscosity was 50 poise, the peroxydicarbonate concentration was 14.8% by weight and 90 mis of water was obtained from the bottom of the container. Reincorporating the water gave a suspension from which 30 mis. of water was tapped after a further months standing. EXAMPLE 5 A stirred mixture of 400 g of dilauroyl peroxide and 565 g of water was passed through the colloid mill. The effluent was collected in a stirred vessel and to it was added 15 g off sorbitan monolaurate and 20 g of methyl cellulose. After 15 minutes stirring this mixture was passed through the colloid. ill. The resulting smooth free flowing homogenous dispersion had a viscosity of 150 poise and analysed at 39.6% by weight dilauroyl peroxide. After four months standing the peroxide content has only dropped to 39.5% by weight, the viscosity was 130 poise and 30 mis of water was obtained from the bottom of the container. This was readily reinσor orable with shaking to give a dispersion that separated only 10 mis of water with a further months standing. EXAMPLE 6 A stirred mixture of 500 g of dibenzoyl peroxide and 465 g of water were passed through a colloid mill. The effluent was collected in a stirred vessel and to it was 5 added 15 g of sorbitan monolaurate and 20 g of methyl cellulose. Processing as in Example 5 gave a suspension of viscosity 200 poises, 50.1% by weight benzoyl peroxide and which separated 75 mis of water over four months standing. Reincorporation of the water yielded a 10 suspension that separated 20 mis of water over a further months standing. EXAMPLE 7 A stirred mixture of 775 g of water and 30 g of dilauroyl peroxide was passed through a colloid mill. 15. This was collected in a stirred vessel and 170 g of dicetyl peroxydicarbonate was added to it. When all the organic peroxide appeared well suspended 5 g of glycerol monostearate followed by 20 g of hydroxypropylmethyl cellulose was added. After 15 minutes of stirring the 20 mixture was passed through a colloid mill. A smooth free flowing dispersion of viscosity 85 poise was obtained. Iodimetric analysis indicated an appropriately balanced composition of the two organic peroxides. After four months standing 45 is of water 25 could be tapped from the bottom of the container. Re-adding the water to the container and shaking by hand for 30 seconds produced a homogenous dispersion which had only separated 15 mis of water after another months standing. 30 EXAMPLE 8 Following the method outlined in Example 7, 775 g of water, 30 g of dilauroyl peroxide, 170 g of bis (4-tert-butylcyclohexyl) peroxydiσaroonate, 5 g of sorbitan monolaurate and 20 g of- hy roxyethyl cellulose 35 were mixed together and homogenised. The resulting dispersion had a viscosity of 65 poise. Iodimetric analysis indicated an appropriately balanced composition of the two organic peroxides. After four months standing 25 mis of water could be tapped from the bottom of the container. Reincorporating the water produced a homogenous dispersion which had only separated 20 mis of water after another months standing. In closing, it is again emphasised that, as long as the basic premise is observed (viz. dispersability of the organic peroxide(s) into water using only a protective colloid and a surfactant as herein indicated) , all matters of detail falling therewithin, not being critical in themselves, can be varied in accordance with situational requirements. From the foregoing, it should be evident that, by the invention, a substantive constribution to the art has been made.

Claims: CLAIMS 1. A process for the production of a stable, pumpable, aqueous suspension of an organic peroxide or of mixed organic peroxides, which suspension is especially suitable for the polymerisation of vinyl chloride monomer to form a polyvinyl chloride meeting the specifications required of electrical cable sheathing materials and is also suitable for the polymerisation/copolymerisation of ethylenically unsaturated monomers to form general purpose polymers, the said process being characterised in that the aqueous suspension is made to contain one or more organic peroxides, at least one protective colloid and a surfactant (as herein defined) selected from the group consisting of fatty acid esters of polyhydric alcohols, and alkanolamides. 2. A process for the production of a stable, pumpable, aqueous suspension of an organic peroxide or of mixed organic peroxides, which suspension is especially suitable for the polymerisation of vinyl chloride monomer to form a polyvinyl chloride meeting the specifications required of electrical cable sheathing materials and is also suitable for the polymerisation/copolymerisation of ethylenically unsaturated monomers to form general purpose polymers, the said process being characterised in that the aqueous suspension is made to contain 5 to 50% by weight of one or more organic peroxides, 0.1 to 10% by weight of at least one protective colloid, and 0.1 to 5% by weight of a surfactant (as herein defined) selected from the group consisting of fatty acid esters of polyhydric alcohols, and alkanolamides. 3. A process as claimed in claim 1 or 2 wherein the surfactant is a single surfactant. 4. A process as claimed in any one of claims 1 to 3 wherein the percentage by weight of peroxide component is in the range 10 to 50%. 5. A process as claimed in any one of claims 1 to 4 wherein tne percentage by weight of protective colloid component is in the range of 0.5 to 5%. 6. A process as claimed in any one of claims 1 to 5 wherein the percentage by weight of surfactant component is 0.25 to 2%. 7. A process as claimed in any one of the preceding claims wherein the organic peroxide component is selected from peroxydicarbonates, aliphatic diacyl peroxides and aromatic diacyl peroxides. 8. A process as claimed in any one of the preceding claims wherein the protective colloid component is selected from hydroxylated alkyl celluloses, natural products and suspending agents. 9. A process for the production of a stable, pumpable, aqueous suspension of an organic peroxide or of mixed organic peroxides substantially as herein described with reference to any one of the foregoing Examples thereof. 10. A stable, pumpable, aqueous suspension of an organic peroxide or of mixed organic peroxides, which suspension is especially suitable for the polymerisation of vinyl chloride monomer to form a polyvinyl chloride meeting the specifications required of electrical cable sheathing materials and is also suitable for the polymerisation/co¬ polymerisation of ethylenically unsaturated monomers to form general purpose polymers, said suspension comprising one or more organic peroxides, at least one protective colloid and a surfactant (as herein defined) selected from the group consisting of fatty acid esters of polyhydric alcohols, and alkanolamides. 11. A stable, pumpable, aqueous suspension of an organic peroxide or of mixed organic peroxides, which suspension is especially suitable for the polymerisation of vinyl chloride monomer to form a polyvinyl chloride tr.eeting the specifications required of electrical cable sheathing materials and is also suitable for the polymerisation/copolymerisation of ethylenically unsaturated monomers to form general purpose polymers, such suspension comprising 5 to 50% by weight of one or more organic peroxides, 0.1 to 10% by weight of at least one protective colloid, and 0.1 to 5% by weight of surfactant (as herein defined) selected from the gro consisting of fatty acid esters of polyhrdric alcohol and alkanolamides. 12. A suspension as claimed in claims 10 or 11 where the surfactant is a single surfactant. 13. A suspension as claimed in any one of claims 10 to wherein the percentage by weight of peroxide component in the range 10 to 50%. 14. A suspension as claimed in any one of claims 10 to wherein the percentage by weight of protective collo component is in the range 0.5 to 5%. 15. A suspension as claimed in any one of claims 10 to wherein the percentage by weight of surfactant compone is 0.25 to 2%. 16. A suspension as claimed in any one of claims 10 to wherein the organic peroxide component is selected fr peroxydicarbonates, aliphatic diacyl peroxides a aromatic diacyl peroxides. 17. A suspension as claimed in any one of claims 10 to wherein the protective colloid component is selected fr hydroxylated alkyl celluloses, natural products a suspending agents. 13. A stable, pumpable, aqueous suspension of an organ peroxide or of mixed organic peroxides, substantially herein described with reference to an one of t foregoing Examples thereof. 19. A process for the polymerisation of vinyl cnlori monomer to form a polyvinyl chloride meeting t specifications required of electrical cable sheathi materials or for the polymerisation /copoiymerisation ethylenically unsaturated monomers to form general purpo polymers, wherein there is employed, as initiator, suspension in accordance with any one of claims 10 to or produced by the process of any one of claims 1 to 9. 20. A product made by the process of claim 19.

Inventors: LAAR H
Applicants: INTEROX CHEM PTY LTD, LAAR H
Application year: 1981
Main classification: B01F17
IPC codes: B01F17, C07C67, C07C407, C07C409, C08F2