Polymerization process involving diacyl peroxides

1. Process comprising the steps of:

producing an aqueous mixture comprising a diacyl peroxide of formula (I)

 wherein R 1 –R 4 are independently selected from the group consisting of hydrogen, halogen, and saturated or unsaturated, linear or branched alkyl, alkaryl, and aralkyl moieties optionally substituted with one or more halogen atoms, provided that if R 1 and/or R 2 are hydrogen, then R 3 and/or R 4 are not hydrogen and, vice-versa, that if R 3 and/or R 4 are hydrogen, then R 1 and/or R 2 are not hydrogen, in which process R 1 —C—R 2 and/or R 3 —C—R 4 can be part of a ring structure that can be saturated or unsaturated and substituted with one or more independently chosen groups R 1 , or one of R 1 —C(R 2 )H and R 3 —C(R 4 )H represents an, optionally substituted, aromatic ring structure, with the further proviso that diacyl peroxides of formula (I) wherein R 2 is halogen and R 4 is hydrogen, and both R 1 and R 3 are long chain alkyl groups having about 10 to about 16 carbon atoms, are excluded, by reacting, in a so-called peroxidation step, one or more acid halides of formula

 wherein X is halide, preferably chloride or bromide, most preferably chloride, with i) MOOH/M 2 O 2 , wherein M is any metal or ammonium-containing group that will react with H 2 O 2 to form MOOH/M 2 O 2 without decomposing one or more of the peroxides present in the process, preferably M is selected from the group consisting of ammonium, sodium, potassium, magnesium, calcium, and lithium, and optionally ii) one or more peracids of formula (III)

 or the M salts thereof, in an aqueous phase, in which process the acid halide, or mixture of acid halides, is essentially only brought into contact with water containing MOOH/M 2 O 2 and/or one or more peracids or peracid salts, preferably M 2 O 2 or the M salt of the peracid,

optionally introducing one or more solvents for the acid halide in any part of the process,

optionally introducing one or more salts in any part of the process,

optionally introducing one or more colloids and/or surfactants, before, during, or after the peroxidation step,

optionally purifying the aqueous mixture in one or more purification steps,

optionally homogenizing the aqueous mixture in one or more homogenization steps,

transferring the product from the previous steps that comprises the diacyl peroxide of formula (I) to a polymerization reactor, and

thermally decomposing said diacyl peroxide, to generate organic free radicals, in the presence of one or more ethylenically unsaturated monomers, to polymerize said monomers in said polymerization reactor.

2. Process comprising the steps of:

producing an aqueous mixture comprising a diacyl peroxide of formula (I)

 wherein R 1 –R 4 are independently selected from the group consisting of hydrogen, halogen, and saturated or unsaturated, linear or branched alkyl, alkaryl, and aralkyl moieties optionally substituted with one or more halogen atoms, provided that if R 1 and/or R 2 are hydrogen, then R 3 and/or R 4 are not hydrogen and, vice-versa, that if R 3 and/or R 4 are hydrogen, then R 1 and/or R 2 are not hydrogen, in which process R 1 —C—R 2 and/or R 3 —C—R 4 can be part of a ring structure that can be saturated or unsaturated and substituted with one or more independently chosen groups R 1 , or one of R 1 —C(R 2 )H and R 3 —C(R 4 )H represents an, optionally substituted, aromatic ring structure, with the further proviso that if R 2 is halogen and R 4 is hydrogen, and both R 1 and R 3 are alkyl groups, then each of these alkyl groups has up to about 6 carbon atoms, by reacting, in a so-called peroxidation step, one or more acid halides of formula (II)

wherein X is halide, preferably chloride or bromide, most preferably chloride, with i) MOOH/M 2 O 2 , wherein M is any metal or ammonium-containing group that will react with H 2 O 2 to form MOOH/M 2 O 2 without decomposing one or more of the peroxides present in the process, preferably M is selected from the group consisting of ammonium, sodium, potassium, magnesium, calcium, and lithium, and optionally ii) one or more peracids of formula (III)

or the M salts thereof, in an aqueous phase, in which process the acid halide, or mixture of acid halides, is essentially only brought into contact with water containing MOOH/M 2 O 2 and/or one or more peracids or peracid salts, preferably M 2 O 2 or the M salt of the peracid,

optionally introducing one or more solvents for the acid halide in any part of the process,

optionally introducing one or more salts in any part of the process,

optionally introducing one or more colloids and/or surfactants, before, during, or after the peroxidation step,

optionally purifying the aqueous mixture in one or more purification steps,

optionally homogenizing the aqueous mixture in one or more homogenization steps,

transferring the product from the previous steps that comprises the diacyl peroxide of formula (I) to a polymerization reactor, and

thermally decomposing said diacyl peroxide, to generate organic free radicals, in the presence of one or more ethylenically unsaturated monomers, to polymerize said monomers in said polymerization reactor.

3. Process comprising the steps of:

producing an aqueous mixture comprising a diacyl peroxide of formula (I)

 wherein R 1 –R 4 are independently selected from the group consisting of hydrogen and saturated or unsaturated, linear or branched alkyl, alkaryl, and aralkyl moieties optionally substituted with one or more halogen atoms, provided that if R 1 and/or R 2 are hydrogen, then R 3 and/or R 4 are not hydrogen and, vice-versa, that if R 3 and/or R 4 are hydrogen, then R 1 and/or R 2 are not hydrogen, in which process R 1 —C—R 2 and/or R 3 —C—R 4 can be part of a ring structure that can be saturated or unsaturated and substituted with one or more independently chosen groups R 1 , or one of R 1 —C(R)H and R 3 —C(R 4 )H represents an, optionally substituted, aromatic ring structure, by reacting, in a so-called peroxidation step, one or more acid halides of formula (II)

 wherein x is halide, preferably chloride or bromide, most preferably chloride, with i) MOOH/M 2 O 2 , wherein M is any metal or ammonium-containing group that will react with H 2 O 2 to form MOOH/M 2 O 2 without decomposing one or more of the peroxides present in the process, preferably M is selected from the group consisting of ainmonium, sodium, potassium, magnesium, calcium, and lithium, and/or ii) one or more peracids of formula (III)

or the M salts thereof, in an aqueous phase, in which process the acid halide, or mixture of acid halides, is essentially only brought into contact with water containing MOOH/M 2 O 2 and/or one or more peracids or peracid salts, preferably M 2 O 2 or the M salt of the peracid,

optionally introducing one or more solvents for the acid halide in any part of the process,

optionally introducing one or more salts in any part of the process,

optionally introducing one or more colloids and/or surfactants, before, during, or after the peroxidation step,

optionally purifying the aqueous mixture in one or more purification steps,

optionally homogenizing the aqueous mixture in one or more homogenization steps,

transferring the product from the previous steps that comprises the diacyl peroxide of formula (I) to a polymerization reactor, and

thermally decomposing said diacyl peroxide, to generate organic free radicals, in the presence of one or more ethylenically unsaturated monomers, to polymerize said monomers in said polymerization reactor.

4. A process according to claim 1 wherein the diacyl peroxide obtained in the peroxidation step is used in the polymerization process within a period of 168 hours after said peroxidation step.

5. A process according to claim 1 wherein the diacyl peroxide is stored and handled in this process at temperatures up to 5° C.

6. A process according to claim 1 wherein one and the same reactor is used to make the MOOH/M 2 O 2 from a source of M and H 2 O 2 and to carry out the peroxidation step.

7. A process according to claim 1 wherein 0.005 to 2% w/w of the diacyl peroxide is used in the polymerization step, based on the weight of the ethylenically unsaturated monomer(s).

8. A process according to claim 1 wherein the ethylenically unsaturated monomer(s) comprise(s) vinyl chloride monomer.

9. A process according to claim 1 wherein at least one acid halide is used that is selected from the group consisting of lauroyl halide, isobutanoyl halide, 2-ethylbutanoyl halide, 2-ethylhexanoyl halide, 2-chloropropanoyl halide, cyclohexane carbonyl halide, 3-methylcyclohexane carbonyl halide, and 2,3-dihalocyclohexane carbonyl halide.

10. A process according to claim 1 wherein at least one resulting diacyl peroxide is asymmetrical.

11. A process according to claim 10 wherein a peracid is used in the peroxidation step.

12. A process according to claim 1 that is essentially solvent-free.

13. A process according to claim 1 wherein the diacyl peroxide is dosed to the polymerization reaction mixture at the reaction temperature.

14. A process according to claim 3 wherein the diacyl peroxide obtained in the peroxidation step is used in the polymerization process within a period of 168 hours after said peroxidation step.

15. A process according to claim 3 wherein the diacyl peroxide is stored and handled in this process at temperatures up to 5° C.

16. A process according to claim 3 wherein one and the same reactor is used to make the MOOH/M 2 O 2 from a source of M and H 2 O 2 and to carry out the peroxidation step.

17. A process according to claim 3 wherein 0.005 to 2 % w/w of the diacyl peroxide is used in the polymerization step, based on the weight of the ethylenically unsaturated monomer(s).

18. A process according to claim 3 wherein the ethylenically unsaturated monomer(s) comprise(s) vinyl chloride monomer.

19. A process according to claim 3 wherein at least one acid halide is used that is selected from the group consisting of lauroyl halide, isobutanoyl halide, 2-ethylbutanoyl halide, 2-ethylhexanoyl halide, 2-chloropropanoyl halide, cyclohexane carbonyl halide, 3-methylcyclohexane carbonyl halide, and 2,3-dihalocyclohexane carbonyl halide.

20. A process according to claim 3 wherein at least one resulting diacyl peroxide is asymmetrical.

21. A process according to claim 3 that is essentially solvent-free.

22. A process according to claim 3 wherein the diacyl peroxide is dosed to the polymerization reaction mixture at the reaction temperature.