Terpolymers containing sulfonate functionality and process for their preparation.

Abstract: Terpolymers of acrylamide, an alkylacrylamide and an ethylenically unsaturated sulfonate-containing monomer are made by forming a homogeneous solution of them in de-oxygenated water, using a suitable anionic or nonionic surfactant or a mixture of both, under an atmosphere of nitrogen; adding free radical initiator to initiate polymerization of said monomers; and copolymerizing at a temperature of about 10°C to 90°C to form the terpolymer.

Description: The present invention relates to terpolymers for use as viscosifying agents for aqueous and brine media, and to a process for their preparation. European published patent application EP-A-115 213 describes copolymers of acrylamide and alkyl acrylamide for use as a viscosifier for aqueous and brine solutions, and describes a microemulsion, free radical copolymerisation process for the preparation of the copolymers. US patent 4,293,427 describes a copolymer of a (meth)acrylamido alkyl sulfonic acid or an alkali metal salt thereof and either a (meth)acrylamide or a C₁₋₃ alkyl (meth)acrylamide for use as a filtration control agent in oil well drilling. The copolymer, together with the other drilling fluid constituents, acts to produce a filter cake along the bore hole to maintain effective filtration control during circulation of the drilling fluid within the well. The copolymer does not materially affect the viscosity of the drilling fluid. SUMMARY OF THE INVENTION A process is described for producing unique and novel sulfonate containing terpolymers of water soluble monomers with water insoluble monomers which are efficient viscosifiers of aqueous and brine media. The process relies on the complete solubilization of the water insoluble monomer by means of a dilute solution of a suitable water soluble surfactant. The type and concentration of surfactant are chosen to produce a clear, uniform, homogeneous aqueous dispersion of the hydrophobic monomers in the presence of both nonionic and anionic water soluble monomers and, in addition, the reaction medium remains a clear, uniform, homogenous mixture with no phase separation as the reaction proceeds to completion. The micelles formed by the surfactant are small aggregates, consisting of in the order of 50 to 200 molecules. They are stable toward phase separation and effectively disperse the water insoluble monomer on a very fine scale so that the terpolymerization is effected without the formation of latexes or fine particulates of water insoluble polymer. This invention describes novel hydrophobically associating terpolymer compositions containing sulfonate functionality. The polymers consist of a water soluble nonionic monomer, such as acrylamide, a water soluble anionic sulfonate monomer, such as sodium 2-acrylamido-2-methylpropane sulfonate, and an oil soluble hydrophobic alkylacrylamide monomer. These terpolymers provide efficient viscosification of water or brine solutions. The anionic sulfonate groups improve polymer solubility in water and brine, particularly in the presence of salts containing divalent cations, and impart some chain stiffness due to charge repulsion, particularly in water containing a low electrolyte concentration. The hydrophobic N-alkylacrylamide groups associate in solution to create a structure with an apparent increase in molecular weight, resulting in enhanced thickening efficiency. Thus, the anionic sulfonate groups and hydrophobic groups are balanced to provide water and brine solubility, along with excellent thickening efficiency. In addition, aqueous fluids thickened with the polymer compositions of this invention have improved mechanical stability when subjected to high shear and better salt tolerance relative to polymers relying on molecular weight in place of the hydrophobic associations for viscosification. DETAILED DESCRIPTION OF THE INVENTION According to the process of the present invention as claimed, there is provided a homogeneous micellar free radical polymerization process for the formation of a water-soluble terpolymer of water-soluble acrylamide, a water-insoluble alkylacrylamide and a water-soluble ethylenically unsaturated sulfonate-containing monomer which comprises the steps of: a. forming a homogeneous aqueous dispersion in deoxygenated water of acrylamide, an alkylacrylamide and an ethylenically unsaturated sulfonate containing monomer using a suitable anionic surfactant or a mixture of anionic and nonionic surfactants under an atmosphere of nitrogen; b. adding free radical initiator to said homogeneous reaction mixture to initiate polymerization of said monomers; c. copolymerizing said monomer mixture at a temperature of from 0°C to 90°C to form the terpolymer. The resulting terpolymer of acrylamide, a salt of an ethylenically unsaturated alkyl or aryl sulfonic acid and a hydrophobic N-alkylacrylamide can be isolated from the reaction mixture by any of a variety of techniques which are well known to one skilled in the art. For example, the polymer may be recovered by precipitation using a nonsolvent, such as acetone, methanol, isopropanol or mixtures thereof. The precipitated polymer can then be washed and oven dried to provide a product in the form of a free flowing powder. Alternatively, the polymer solution may be used as is by diluting with the desired aqueous solvent to the concentration of use. The present invention describes the terpolymerization of nonionic, water soluble acrylamide; a water soluble, anionic ethylenically unsaturated alkylsulfonate monomer, such as salts of 2-acrylamido-2-methylpropane sulfonate; and a water insoluble alkylacrylamide which preferably has a carbon chain length of 6 or greater. The resulting terpolymers are efficient viscosifiers of water and brine. The process for synthesizing these terpolymers relies on solubilizing the water insoluble monomer into a predominantly aqueous media by the use of a suitable water soluble surfactant, such as sodium dodecyl sulfate. When mixed with an aqueous solution of the water soluble acrylamide monomer and the water soluble sulfonate monomer, the surfactant solution can disperse the water insoluble monomer on an extremely fine scale so that the reaction mixture is isotropic, clear and homogeneous. These micellar reaction mixtures are free of visible oil droplets or particulates of the water insoluble monomer. The terpolymerization can, therefore, be initiated by water soluble initiators to yield terpolymers which are substantially free of visible particulates. The resultant reaction mixture remains homogeneous throughout the course of the reaction without the need for agitation with external mixers or stirrers. Micelles formed by the surfactant which solubilize the water insoluble monomer are generally small aggregates which consist of on the order of 50 to 200 molecules. They may assume a variety of shapes, from spherical to rod-like or cylindrical, and generally are in the size range of from about 20 Angstroms to 500 Angstroms in diameter. These micelles form spontaneously upon mixing the components together, i.e., they do not require the vigorous mixing conditions required in conventional emulsion polymerization in which macroemulsions are formed. The macroemulsion droplets of the conventional emulsion polymerization process have diameters which are at least 10,000 Angstroms. They, therefore, tend to phase separate upon standing, leading to undesirable inhomogenities in the produced copolymer. The homogeneous micellar reaction mixture is, on the other hand, much more stable against demixing than the formulations used in emulsion polymerization processes. Indeed, no stirring is required during the course of the micellar copolymerization - the micellar aggregates remain extremely finely dispersed throughout. Moreover, the finely dispersed nature of the micellar aggregates permit the terpolymerization to occur in such a way that a water soluble terpolymer is produced which does not contain particulates or latexes of water insoluble polymers. These would be detrimental in such applications as secondary oil recovery, which requires a product which is substantially free of pore plugging particulates. The surfactants which may be used in this process may be one of the water soluble surfactants, such as salts of alkyl sulfates, sulfonates and carboxylates, or alkyl arene sulfates, sulfonates or carboxylates. Preferred are sodium or potassium salts of decyl sulfate, dodecyl sulfate or tetradecylsulfate. For these ionic surfactants the Krafft point, which is defined as the minimum temperature for micellar formation, must be below the temperature used for the polymerization. Thus, at the conditions of polymerization the desired surfactant will form micelles which solubilize the water insoluble monomer. Nonionic surfactants can also be used for preparing the polymers of this invention. For example, ethoxylated alcohols, ethoxylated alkyl phenols, ethoxylated dialkyl phenols, ethylene oxide-propylene oxide copolymers and polyoxyethylene alkyl ethers and esters can be used. Preferred nonionic surfactants are ethoxylated nonyl phenol with 5 to 20 ethylene oxide units per molecule, ethoxylated dinonyl phenol containing 5 to 40 ethylene oxide units per molecule and ethoxylated octyl phenol with 5 to 15 oxide units per molecule. Surfactants which contain both nonionic and anionic functionality, e.g., sulfates and sulfonates of ethoxylated alcohols and alkyl phenols, can also be used. Combinations of anionic and nonionic surfactants can also be used, as long as the surfactants solubilize the hydrophobic monomer into an aqueous phase containing the water soluble monomers. The surfactant or mixtures of surfactants will be used at concentrations above their critical micelle concentration and preferably at concentrations such that only one hydrophobic monomer is associated with a surfactant micelle. Thus, the actual concentration of surfactant for a given polymerization will depend on the concentration of oil soluble or hydrophobic monomers employed. Polymerization of the water soluble and water insoluble monomers is effected in an aqueous micellar solution containing a suitable free radical initiator. Examples of suitable water soluble free radical initiators include peroxides, such as hydrogen peroxide, and persulfates, such as sodium, potassium or ammonium persulfate. The concentration of the free radical initiator is preferably about 0.01 to about 0.5 grams per hundred grams of total monomers. Suitable oil soluble initiators are organic peroxides and azo compounds, such as azobisisobutyronitrile. Water soluble initiators are preferred, such as potassium persulfate. Redox initiation involving an oxidant, such as potassium persulfate, and a reductant, such as sodium metabisulfite, can also be used to initiate polymerization, particularly at low temperatures. Polymerizing at lower temperatures results in the formation of higher molecular weight polymers which are desirable from the standpoint of efficient aqueous viscosification. Typically, it is desired to employ from about .01 to about 0.5 weight percent of initiator, based on the weight of monomers. The polymerization temperature is from 0°C to 90°C, preferably 20°C to 80°C, and more preferably 25°C to 70°C. The time required will normally be no longer than that after which substantial amounts of particulates form or phase separation occurs. The water insoluble terpolymers which are produced by the micellar terpolymerization process of the instant invention are characterized by the formula: A = SO₃M, phenyl-SO₃M, CONHC(CH₃)₂CH₂SO₃M wherein R₁ is preferably a C₆ to C₂₂ straight chained or branched alkyl or cycloalkyl group, more preferably a C₆ to C₂₀, and most preferably a C₆ to C₁₈; R₂ is the same or different alkyl group as R₁, or hydrogen or C₁ to C₃ straight chained or branched alkyl group; and M is an alkali metal or ammonium cation. Typical, but nonlimiting, examples of preferred alkyl groups are hexyl, octyl, decyl, dodecyl and hexadecyl groups. Typical, but nonlimiting, examples of preferred cations are sodium, potassium and ammonium. The mole percentage of acrylamide, x, is preferably at least 5, more preferably 10 to 90, and most preferably 20 to 80. The mole percentage of the salt of the sulfonate containing monomer, y, is preferably 2 to 95, more preferably 5 to 90, and most preferably 10 to 80. The mole percentage of the hydrophobic group, z, is preferably 0.1 to 10.0, more preferably 0.2 to 5.0, and most preferably 0.2 to 3.0. The molecular weight of the water soluble terpolymers produced by the process of this invention is sufficiently high that they are efficient viscosifiers of water or brine, but not so high that the polymer molecules are readily susceptible to irreversible shear degradation. Thus, the weight average molecular weights are preferably about 200,000 to about 10,000,000, more preferably about 500,000 to about 8,000,000, and most preferably about 1,000,000 to about 7,000,000. The intrinsic viscosity of these polymers as measured in 2% sodium chloride solution is preferably greater than about 1 dl/gm. The hydrophobically associating terpolymer compositions produced by the micellar polymerization process of this invention have been found useful for thickening aqueous fluids. To prepare these thickened fluids, an amount of the terpolymer thickening agent is dissolved in the aqueous fluid by agitation, using any of a number of techniques well known in the art. For example, a marine impellor operating at relatively low speed can be used to first disperse and then dissolve these hydrophobically associating terpolymers. It is desirable to use relatively low agitation conditions since these polymers have a tendency to cause and stabilize foams which can be difficult to break. The aqueous solutions may be distilled water or high concentrations of electrolyte in water, such as in hard water or brine. Monovalent inorganic salts, such as sodium chloride, and divalent salts, such as calcium or magnesium chloride or sulfate, can be present in the brine in substantial amounts. A preferred method for preparing the thickened brine solutions involves first preparing a concentrated solution of the polymers in relatively fresh water and then adding a concentrated brine solution to obtain the desired final thickened brine solution. The amount of polymeric thickening agent needed to produce a desired level of viscosification will depend on the composition of the electrolytes in the aqueous fluid and the temperature. In general, more polymer will be required as the electrolyte concentration increases and as the temperature increases. Viscosification of about 2 to about 100 times or more that of the neat solvent can readily be achieved with the terpolymers prepared by the process of this invention. Preferably, about 0.01 to about 2.0 weight percent, more preferably about 0.05 to about 1.0 weight percent, and most preferably about 0.1 to about 0.5 weight percent polymer, based on the aqueous medium, will provide the desired level of thickening efficiency. The thickening efficiency of a given polymer is influenced by the amount of anionically charged sulfonate groups, the level and type of hydrophobic groups and the weight average molecular weight. The addition of the anionic sulfonate groups improves polymer solubility and enhances thickening efficiency due to repulsion of charges along the backbone, which tends to open the polymer coil and increase hydrodynamic volume. The hydrophobic groups decrease polymer solubility and associate in solution to physically bridge polymer molecules, creating greater resistance for flow and, hence, increased viscosity. The more insoluble the hydrophobic group is in the solvent, the less that is needed to create the associations in solution. For example, less dodecylacrylamide is needed in a polymer to create the same viscosification as a larger amount of octylacrylamide in a similar polymer. In addition, it is possible to have too much association, in which case the polymer becomes insoluble in the solvent and cannot be used as a viscosifier. Fortunately, the solubility characteristics of the sulfonate and hydrophobic groups are opposite one another and, thus, the addition of more sulfonate monomer can be used to counterbalance the addition of hydrophobic groups. Increasing both sulfonate and hydrophobic groups can result in a synergistic enhancement of thickening efficiency. Molecular weight of the polymer is also an important consideration. High molecular weight polymers incorporating both anionically charged sulfonate groups and hydrophobic groups can provide significantly improved viscosification of water based fluids. All other things being equal, the higher the molecular weight the less soluble the polymer. Thus, as molecular weight is increased, the amount of hydrophobic groups should be reduced and the amount of sulfonate groups increased. It is desirable that the resulting polymer in an aqueous solution not be susceptible to irreversible mechanical degradation under shear. This places an upper limit on the molecular weight of about 10,000,000. Control of molecular weight is achieved by the concentration of monomers, the type and level of initiator and the reaction temperature. As is well known in the art, the molecular weight is increased by increasing the monomers level and decreasing the initiator level and reaction temperature. To evaluate and characterize the unique and useful properties of the hydrophobically associating polymers of this invention, dilute solution viscometric measurements were made. These measurements were particularly useful for evaluating the effect of composition and polymerization process conditions on the hydrodynamic size of the polymer in solution and the influence of associating groups. The hydrodynamic size is measured by the intrinsic viscosity which is proportional to the viscosity average polymer molecular weight. To determine the intrinsic viscosity, the reduced viscosity is first evaluated at several polymer concentrations in the dilute concentration regime. The reduced viscosity is defined as the incremental viscosity increase of the polymer solution relative to the pure solvent normalized with respect to the pure solvent viscosity and the polymer concentration. A plot of reduced viscosity versus polymer concentration should yield a straight line at low polymer concentrations. The intercept of this reduced viscosity plot at zero polymer concentration is defined as the intrinsic viscosity, while the slope is the Huggin's interaction coefficient times the square of the intrinsic viscosity. The Huggins' constant is a measure of polymer-solvent interactions. For hydrophobically associating polymers, it is characteristically greater than the 0.3 to 0.7 value normally observed for non-associating polymers, such as polyacrylamides. Measurement of the dilute solution viscosity can be made with conventional Couette or capillary viscometers. A set of Ubbelohde capillary viscometers were used in this study and shear rate effects were found to be negligible in the concentration range of interest. However, since the terpolymers contain anionically charged groups, a polyelectrolyte effect was observed in dilute solution. The addition of salts, such as sodium chloride or sodium sulphate, shielded the charge repulsion, causing the polyelectrolyte effect and resulted in the desired linear reduced viscosity-concentration profile. The dilute solution measurements were thus made on solutions containing 2.0 weight percent chloride. The solution viscosity of associating polymers in the semi-dilute concentration regime is dramatically different than conventional water soluble polymers. Viscosities of these solutions were measured by means of a Contraves® low shear viscometer, model LS 30, using a No. 1 cup and a No. 1 bob. Temperatures were controlled to ±0.1°C and measurements were made at a variety of rotational speeds corresponding to shear rates from about 1.0 sec⁻¹ to about 100 sec⁻¹. In contrast to conventional water soluble polymers and relatively low molecular weight weakly associating polymers, the terpolymers of this invention can exhibit significant relaxation times which result in slow equilibration. To determine steady state viscosity values at a given stress or shear rate, relatively long measurement times were employed. This effect is most evident at higher polymer concentrations, higher polymer molecular weights and in regions of strong intermolecular hydrophobic associations. DESCRIPTION OF THE PREFERRED EMBODIMENTS The following Examples illustrate the present invention without, however, limiting the same hereto. Example 1 Micellar Polymerization with Sulfonate Containing Monomers Radical Initiation A one liter Morton style kettle, fitted with a chilled water condenser, thermometer, nitrogen sparger, and mechanical stirrer, was charged with 500 ml of purified water. The water was refluxed for 1 hour with a nitrogen purge and then cooled to room temperature. Acrylamide, 8.11 g (0.11 mole), 6.62 g (0.023 mole) of AMPS®, 0.265 g of N-octylacrylamide and 15 g of sodium dodecyl sulfate (SDS) were charged into the flask. The reaction solution was heated to 50°C and 0.0047 g potassium persulfate was added. After 22.75 hours at 50°C and 300 rpm stirring, the viscous solution was slowly poured into 3L of methanol and the precipitated polymer was isolated by filtration. The polymer was then masticated in a Warning blender with 2L of methanol for 30 seconds, filtered and dried under vacuum at room temperature. The yield of polymer was 10.73 g. A variety of terpolymers were prepared using similar procedures but with different amounts of acrylamide, AMPS®, N-octylacrylamide, SDS and initiator levels, as shown in Table I. POLY (N-OCTYLACRYLAMIDE-ACRYLAMIDE-AMPS® TERPOLYMERS Example V- Hydrophobe Mole% AMPS® Mole% SDS Conc. Wt.% Initiator Level [M]/[I]0.5 Yield g % 7181 0.0 20 2.0 49 13.8 92 7182 0.0 20 3.0 49 14.4 96 7185 1.0 20 2.0 49 10.7 71 7198 0.75 20 2.0 49 14.0 93 7199 1.0 30 2.0 49 14.0 93 7202 0.50 20 2.0 49 11.0 73 7203 1.0 10 2.0 49 13.1 87 7208 1.0 20 3.0 49 11.6 77 7220 1.0 20 3.0 49 12.9 86 7272 1.0 20 3.0 49 7.3 49 7273 1.0 10 3.0 49 10.9 73 7274 1.0 30 3.0 49 5.0 33 7275 0.75 20 3.0 49 7.2 48 7276 1.25 20 3.0 49 7.2 48 7277 1.0 20 3.0 100 5.7 38 7278 1.0 20 3.0 49 12.2 81 7279 1.0 10 3.0 49 13.1 87 7280 1.0 30 3.0 49 11.3 75 Example 2 Micellar Polymerization with Sulfonate Containing Monomers Redox Initiation A solution of 15.0 g of SDS in 500 ml of purified, deoxygenated water was prepared and 0.298 g of N-octylacrylamide, 12.24 g of acrylamide and 9.96 g of AMPS® were added. The resulting clear solution was place into a two liter Morton style resin kettle fitted with a chilled water condenser, thermometer, nitrogen sparger and mechanical stirrer. The solution was purged with nitrogen for 0.5 hours at 25.0°C, then 0.0114 g of potassium persulfate and 0.0075 g of sodium metabilsulfite were added. After 16 hours of stirring at 300 rpm and 25.0°C, the reaction mixture was slowly poured in 3L of methanol. The precipitated polymer was isolated and masticated with 1 L of methanol in a Waring blender for 30 seconds, filtered and dried under vacuum at 30°C. The yield of polymer was 15.4 g. A variety of terpolymers were prepared using similar low temperature redox initiation procedures but with different amounts of acrylamide, AMPS®, N-octylacrylamide, SDS and initiator levels, as shown in Table II. POLY (N-OCTYLACRYLAMIDE-ACRYLAMIDE-AMPS®) TERPOLYMERS Exp. No. Hydrophobe Mole % AMPS® Mole% Redox Initiators, Mx105 Yield K₂S₂O₈ Na₂S₂O₅ g % 412SX 1.25 40 4.6 4.6 16.7 67 7364 0.75 20 7.9 7.49 15.5 64 7367 0.0 20 7.4 7.6 16.4 68 7380 0.75 40 8.6 2.3 20.6 82 7381 0.75 40 4.3 4.6 20.5 82 7391 0.75 30 5.5 5.9 14.8 61 7393 0.75 30 5.5 5.9 21.4 68 7394 0.75 20 3.7 4.0 31.9 64 7395 0.75 30 5.5 5.9 12.3 51 7404 1.25 30 5.5 5.9 14.9 63 7405 1.0 40 4.3 4.6 14.0 58 7406 1.25 40 4.3 4.6 15.1 62 7407 1.5 30 5.4 5.9 16.7 68 7416 0.0 30 2.8 3.0 31.8 65 7417 0.0 40 2.2 2.3 38.8 74 7455 0.75 30 5.5 5.9 46.4 94 7458 1.0 40 4.3 4.6 46.2 93 7508 1.0 40 4.3 4.6 46.1 94 7512 1.0 40 4.3 4.6 44.4 91 7513 0.75 40 4.3 4.6 43.2 88 7522 0.75 40 4.3 4.6 44.4 90 7523 0.75 40 4.3 4.6 42.1 87 7529 0.75 40 2.1 2.3 47.0 92 Example 3 Terpolymerization of N-Octylacrylamide-Acrylamide-Vinyl Sulfonate A one liter Morton style resin kettle, fitted with a chilled water condenser, thermometer, nitrogen sparger and mechanical stirrer was charged with 500 ml of purified water. The water was refluxed for 1 hour with a nitrogen purge and then cooled to room temperature. Acrylamide, 9.886 g (0.14 mole), 4.81 g (0.37 mole) of sodium vinyl sulfonate as a 25% solution in water, 0.33 g (0.002 mole) of N-octylacrylamide and 15 g of sodium dodecyl sulfate (SDS) were charged into the flask. The reaction solution was heated to 50°C and 0.01 g potassium persulfate was added. After 17 hours at 50°C and 300 rpm stirring, the viscous solution was slowly poured into 3 L of methanol and the precipitated polymer was isolated by filtration. The polymer was then masticated in a Waring blender with 2 L of methanol for 30 seconds, filtered and dried under vacuum at room temperature. The yield of the polymer was 10.9 g. Example 4 Micellar Polymerization of N-Octylacrylamide-Acrylamide-Sodium Styrene Sulfonate A solution of 15.0 g of SDS in 500 ml of purified, deoxygenated water was prepared and 0.415 g of N-octylacrylamide, 12.73 g of acrylamide and 9.35 g of sodium styrene sulfonate were added. The resulting clear solution was placed in a 2 liter Morton style resin kettle fitted with a chilled water condenser, thermometer, nitrogen sparger and mechanical stirrer. The solution was purged with nitrogen for 0.5 hour at 25°C, then 0.116 g of potassium persulfate and 0.0082 g of sodium metabilsulfite were added. After 16 hours of stirring at 300 rpm and 25°C the reaction mixture was slowly poured into 3 L of acetone. The precipitated polymer was isolated and masticated with 1 L of methanol in a Waring blender for 30 seconds, filtered and dried under vacuum at 30°C. The yield of polymer was 5.14 g. Example 5 Solution Viscometrics Polymer solutions were prepared by the slow addition of a weighted polymer sample to rapidly stirred 2% NaCl solution. Upon complete addition, the stirring was stopped and the flask was sealed under nitrogen. Dissolution was allowed to progress with mild agitation for 24 hours or longer, until solutions were homogeneous and clear. For characterization in brines containing divalent cations a mixture of 3.0% NaCl and 0.3% CaCl₂ was used and designated as 3.3% brine. To prepare these solutions polymers were initially hydrated in water, followed by addition of concentrated brine solution to give the final polymer concentration of 1,500 ppm in 3.3% brine. Viscosities of these solutions were measured by means of a Contraves® low shear viscometer, model LS30, using a No. 1 cup and No. 1 bob. Temperatures were controlled to ⁺_0.1°C and measurements were made at a variety of rotational speeds corresponding to shear rates from about 1.0 sec⁻¹ to about 100 sec⁻¹. In contrast to conventional water soluble polymers and relatively low molecular weight, weakly associating polymers, the terpolymers of this invention can exhibit significant relaxation times, which result in slow equilibration. To determine steady state viscosity values at a given stress or shear rate, relatively long measurement times were employed. This effect is most evident at higher polymer concentrations, higher polymer molecular weights and in regions of strong intermolecular hydrophobic associations. Intrinsic viscosity was determined using Ubbelohde capillary viscometers. The solvent for these measurements was 2% NaCl solutions. The influence of hydrophobic associations and sulfonate monomer content on solution rheological properties is illustrated in Table III. The solution viscosities were measured at shear rates of 1.3 and 11 sec⁻¹ on solutions containing 1,500 ppm polymer in 3.3% brine. The presence of only 0.75 mole percent octylacrylamide has increased the low shear viscosity by more than an order of magnitude, as observed by comparing sample number 7364 and 7367 in Table III. A further increase in viscosity is noted by simultaneously raising both the AMPS® level and hydrophobe content. These significant enhancements in solution viscosity are due to changes in solubility and hydrophobic associations and have little to do with polymer molecular weight. This is indicated by the approximately constant value of the intrinsic viscosity, which is a measure of molecular weight. The presence of associations is evidenced by the jump in the Huggins coefficient from 0.4, for the nonassociating polymers, to about 1.5, for the associating polymers. The synthesis conditions can have a dramatic effect on polymer molecular weight. Increasing reactor monomer concentration brought about significant increases in solution viscosity, as shown in Table IV, for a series of terpolymers containing 30 mole percent AMPS® and 0.75 mole percent C₈Am. A linear response of solution viscosity was observed as the monomer concentration was increased from 4.5 to 9 weight percent. Doubling the monomer concentration from 4.5 to 9 weight percent resulted in a five-fold increase in viscosity at 11 sec⁻¹. Thus, the control of sulfonate monomer and hydrophobe monomer incorporation, as well as molecular weight, as taught in this invention, provide polymers which impart unique and useful rheological properties to aqueous solutions. Example 6 EFFECT OF AMPS® CONTENT ON MICELLAR POLYMERIZATION The effect of the amount of AMPS® in the terpolymer on the solution viscosity in brine was to decrease the viscosity with increased AMPS®, as shown in Table V. The experiments were done at a constant concentration (4.5 weight percent) of total monomers and C₈AM charge (0.75 mole percent). The loss of viscosification efficiency with increasing AMPS® content could be explained on the basis of decreased molecular weight and associations. Although either cause is plausible, the effect still needs to be overcome. As described in Examples 5 and 7, this loss of viscosification can be compensated for by adjustment of reactor monomer concentration and hydrophobe level, respectively. EFFECT OF AMPS® ON TERPOLYMER SOLUTION VISCOSITY Example No. AMPS® Mole% Viscosity, cP at 1,500 ppm in 3.3% Brine 1.3 sec⁻¹ 11 sec ⁻¹ 7364 20 73 25 7391 30 8 7 7381 40 6 5 Example 7 EFFECT OF HYDROPHOBIC MONOMER CONCENTRATION The influence of hydrophobe level on polymer solution viscosity can be seen from the data in Table VI for two series of polymers containing 30 and 40 mole percent AMPS®, respectively. The total monomer concentration was held at 4.5 weight percent and the hydrophobe, N-1-octylacrylamide, concentration was varied from 0 to 1.5 mole percent. The maximum response in viscosity occurred at 1.0% for 30 mole percent AMPS® and 1.25% for the 40 mole percent AMPS® series. The viscometric data further indicates that the increase in viscosification occurs at a relatively narrow level of hydrophobic groups which depends on the level of sulfonate monomer in the polymer. This is unexpected based on the prior art. EFFECT OF HYDROPHOBIC MONOMER CONCENTRATION Exp. No. N-C8AM Mole% AMPS® Mole% Viscosity, cP at 1,500 ppm in 3.3% Brine 1.3 sec⁻¹ 11 sec ⁻¹ 7416 0 30 5 5 7391 0.75 30 8 7 7395 1.0 30 378 54 7404 1.25 30 79 25 7407 1.5 30 13 8 7417 0 40 4 4 7380 0.75 40 6 5 7405 1 40 7 6 412SX 1.25 40 279 44 Example 8 EFFECT OF SURFACTANT LEVEL The concentration of surfactant used during micellar polymerization can have a significant effect on the resultant hydrophobe-containing polymer. The solution viscosity data in Table VII are for a series of 40 mole percent AMPS® terpolymers at two levels of hydrophobe, 0.75 and 1.0 mole percent. At 0.75 mole percent C₈Am maximum viscosity was achieved at a sodium dodecyl sulfate (SDS) concentration of 2 weight percent. Increasing the hydrophobe level required 3 weight percent SDS to achieve maximum viscosity. The solution clarity of hydrophobically associating polymers can be used as a measure of polymer stability. Thus, low concentrations of surfactant used during micellar polymerization result in polymers with poor solubility in brine. The brine solutions of these polymers are turbid and less viscous. As the surfactant concentration is increased during polymerization, the brine solutions of the resultant polymers become clearer. It can also be seen that there is an optimum concentration of surfactant at which the maximum solution viscosity is attained. The optimum surfactant concentration is a function of the hydrophobe content of the polymer; the optimum surfactant concentration increases as the hydrophobe concentration increases. In addition, the optimum type and content of surfactant used in the micellar polymerization is a function of the type and amount of sulfonate monomer. Example 9 TERPOLYMERIZATION OF N-ALKYLACRYLAMIDE, ACRYLAMIDE AND AMPS® A solution of 15.0 g of SDS in 500 ml of purified, deoxygenated water was prepared and N-alkylacrylamide, acrylamide and 2-acrylamido 2-methylpropane sulfonate were added. The resulting clear solution was placed into a 2 liter Morton style resin kettle fitted with a chilled water condenser, thermometer, nitrogen sparger and mechanical stirrer. The solution was purged with nitrogen for 0.5 hours at 25°C, then potassium persulfate and sodium metabisulfite were added. After 16 hours of stirring at 300 rpm and 25°C, the reaction mixture was slowly poured into 3 L of methanol. The precipitated polymer was isolated and masticated with 1 L of methanol in a Waring blender for 30 seconds, filtered and dried under vacuum at 30°C. A variety of terpolymers were prepared using similar low temperature redox initiation procedures, but with different types and amounts of N-alkylacrylamide hydrophobes and amounts of acrylamide, AMPS®, SDS and initiator levels, as shown in Table VIII. ADDITIONAL HYDROPHOBIC POLYMERS Exp. No. HYDROPHOBE, TYPE MOLE% AMPS® MOLE% Redox Initiators, Mx10⁵ Yield K₂S₂0₈ Na₂S₂O₅ g % 7515 C₆AM 0.75 20 7.9 7.9 16.4 73 7521 C₆AM 1 20 7.9 7.9 14.2 63 7527 C₆AM 1.5 20 7.8 7.8 16.5 73 7533 C₆AM 2 20 7.7 7.8 17.0 76 7494 t-C₈AM 0.75 20 7.9 7.9 16.9 75 7552 t-C₈AM 3 40 4.1 4.4 36.7 82 7553 t-C₈AM 4 40 4.1 4.4 37.2 83 7545 t-C₈AM 5 40 4.0 4.3 32.6 72 7517 C₁₀AM 0.75 20 7.9 7.9 18.0 80 7546 C₁₀AM 0.75 40 4.2 4.5 42.1 94 7503 C₁₂AM 0.25 20 7.4 7.9 18.1 80 7502 C₁₂AM 0.5 20 7.3 7.8 20.5 91 7547 C₁₂AM 0.5 40 4.2 4.5 43.6 97 7550 C₁₂AM 0.5 40 4.2 0.0 44.3 98 7495 C₁₂AM 0.75 20 7.8 7.8 17.4 77 In a preferred form the invention provides a process for producing unique and novel sulfonate containing terpolymers of water soluble monomers with water insoluble monomers which are efficient viscosifiers of aqueous and brine media. A preferred process relies on the complete solubilization of the water insoluble monomer by means of a dilute solution of a suitable water soluble surfactant; the type and concentration of surfactant are chosen to produce a clear, uniform, homogeneous aqueous dispersion of the hydrophobic monomers in the presence of both nonionic and anionic water soluble monomers and, in addition, the reaction medium remains a clear, uniform, homogeneous mixture with no phase separation as the reaction proceeds to completion. In the preferred form, the micelles formed by the surfactant are small aggregates, consisting of in the order of 50 to 200 molecules; they are stable toward phase separation and effectively disperse the water insoluble monomer on a very fine scale so that the terpolymerization is effected without the formation of latexes or fine particulates of water insoluble polymer.

Claims: A homogeneous micellar free radical polymerization process for the formation of a water-soluble terpolymer of water-soluble acrylamide, a water-insoluble alkylacrylamide and a water-soluble ethylenically unsaturated sulfonate-containing monomer which comprises the steps of: a. forming a homogeneous aqueous dispersion in deoxygenated water of acrylamide, an alkylacrylamide and an ethylenically unsaturated sulfonate containing monomer using a suitable anionic surfactant or a mixture of anionic and nonionic surfactants under an atmosphere of nitrogen; b. adding free radical initiator to said homogeneous reaction mixture to initiate polymerization of said monomers; c. copolymerizing said monomer mixture at a temperature of from 0°C to 90°C to form the terpolymer. A process according to claim 1, wherein said free radical initiator is water soluble, and is preferably selected from hydrogen peroxide, and sodium, potassium or ammonium persulfate. A process according to claim 1, wherein said free radical initiator is hydrocarbon soluble, and is preferably selected from azobisisobutyronitrile and benzoyl peroxide. A process according to any preceding claim, wherein said surfactant is an anionic surfactant, and is preferably selected from sodium decylsulfate, sodium dodecylsulfate, sodium tetradecylsulfate, alkyl sulfonates and alkyl aryl sulfonates. A process according to any one of claims 1 to 3, wherein said surfactant is a mixture of anionic and nonanionic surfactants, the anionic surfactant being preferably selected from sodium decylsulfate, sodium dodecylsulfate, sodium tetradecylsulfate, alkyl sulfonates and alkyl aryl sulfonates, and the nonionic surfactant being preferably selected from alkyl ethoxylates and alkyl arene ethoxylates. A process according to any preceding claim for preparing a terpolymer of the formula: wherein A is -SO₃M, -phenyl SO₃M or -CONHC(CH₃)₂CH₂SO₃M, wherein M is an alkali metal or ammonium cation; R₁ is a C₆ to C₂₂ alkyl or cycloalkyl group; R₂ is the same or different alkyl group as R₁ or hydrogen; x is at least 5.0 mole percent; y is 2.0 to 95 mole percent; and z is 0.1 to 10 mole percent. A terpolymer having the formula: wherein B is an ethylenically unsaturated alkyl or aryl sulfonate; wherein R₁ is an alkyl group having 4 to 18 carbon atoms; R₂ is hydrogen or an alkyl group having 4 to 18 carbon atoms; x is 10 mole percent to 90 mole percent; y is 0.1 to 10 mole percent; and z is 5 to 80 mole percent. A solution comprising about 0.5 to about 3.0 grams of a terpolymer dissolved in 100 grams of water, wherein said terpolymer has the formula: wherein R₁ is an alkyl group having 4 to 18 carbon atoms; R₂ is hydrogen or an alkyl group having 4 to 18 carbon atoms; x is 10 to 90; y is 0.1 to 10 mole percent; and z is 5 to 80 mole percent.

Inventors: BOCK JAN, VALINT PAUL LOUIS JR, BOCK, JAN, VALINT, PAUL LOUIS, JR.
Applicants: EXXON RESEARCH ENGINEERING CO, EXXON RESEARCH AND ENGINEERING COMPANY
Application year: 1987
Main classification: C08F220
IPC codes: C08F220, C08F228, C08F28, C08F2, C08F20