Sustainable Polymer Reaction Engineering

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Polymers are found in almost every manufactured product in the world. Not surprisingly, economic indicators for the polymer industry predict a significant global increase in production for the foreseeable future. Most synthetic polymers are derived from petroleum feedstock and we have reached a critical point in our dependence on these feedstock due to supply limitations and negative environmental consequences. The long-term objective of my research program is to develop new methods in sustainable polymerization to provide transformative solutions to the environmental and economic challenges confronting the polymer industry. In a recent review paper, I applied the “12 principles of green chemistry” to current polymer production technology in order to identify research areas with the highest probability of significant impact. This led to the targeting of six of these principles in the current proposal: 1- The design of less hazardous chemical syntheses: Replace hazardous solvents with safer alternatives and monomers with less toxic, typically, bio-based materials. 2- The use of renewable feedstock: It is predicted that the share of total world polymer production occupied by bio-based monomers will increase from 1.5% (2011) to 3% in 2020. Many renewable, bio-based monomers and solvents have already been exploited in my research program (e.g., glycerol, fatty acid methyl esters). 3- The use of catalysts: The presence of allylic moieties in many bio-based monomers leads to degradative chain transfer which impedes polymerization. The use of cationic initiators and living radical polymerization approaches are promising. 4- The use of safer solvents and reaction conditions: Replace solvent-based polymerization methods with water-based (emulsion) polymerization. 5- Increase in energy efficiency: Given the often highly exothermic nature of polymerization reactions, adiabatic operation is an obvious choice to improve energy efficiency. However, the complex temperature-dependent kinetics may lead to serious compromises in product quality. 6- The analysis of process conditions in real-time to prevent pollution: The use of reaction calorimetry and in-line monitoring of polymerization reactions is an area that we continue to actively explore. Given the above principles, I will pursue my long-term objective to develop sustainable polymer reaction engineering technologies. My approach involves using safer solvent alternatives or emulsion polymerization, incorporating renewable materials into polymer products and running reactions adiabatically. My principle target is the production of environmentally benign pressure-sensitive adhesives (PSAs). Four highly innovative projects using emulsion polymerization to produce PSAs will address my objectives: 1. Copolymerization of acrylated methyl oleate and other vegetable oil sources with traditional monomers. 2. Incorporation of terpenes (e.g., alpha-pinene) into copolymer formulations. 3. The use of nitroxide-mediated polymerization for the production of PSAs. 4. Adiabatic emulsion polymerization for PSA production. These approaches have not been studied in the context of PSA production, nor have they been exploited widely for the production of other polymer products. Although Canada possesses abundant renewable resources, the increasing global dependence on non-renewable fossil fuels is leaving an unsustainable social, economic and environmental footprint. The need for immediate action on the stewardship of our planet is obvious, and there is great potential for improvement in the polymer industry. This research will advance Canada’s bio-economy and clean technology by training HQP and maximizing Canada’s performance in an area of emerging environmental and economic importance.