P4 Polymers Properties Polymerisation Processes Imperial College of Science, Technology and Medicine Department of Chemistry Department of Chemical Engineering Centre for Process Systems Engineering

Aim The aim of the project is to exploit new chemistry to produce new or improved polymeric materials as efficiently as possible by integrating the synthesis, scale-up, optimisation and characterisation steps into a connected and iterative loop. Macromolecules to markets!

Interdisciplinary Research Polymerisation chemistryPolymerisation chemistry  J.H.G. Steinke, V.C. Gibson, A.G.M. Barrett Polymerisation reactor engineeringPolymerisation reactor engineering  E. Alpay, J.H.G. Steinke Process systems engineeringProcess systems engineering  S.P Asprey, C.C. Pantelides, E. Alpay Characterisation of polymeric materialsCharacterisation of polymeric materials  J.S. Higgins, R.V. Law, J.H.G. Steinke, V.C. Gibson

P4 Components

P4 Equipment Sulzer Pilot plant flexible reactorSulzer Pilot plant flexible reactor Smaller flexible reactorSmaller flexible reactor Triple detector GPC system from ViscotekTriple detector GPC system from Viscotek High-T MALLS GPC systems from Waters and WyattHigh-T MALLS GPC systems from Waters and Wyatt UV and ELS detectors from Polymer LabsUV and ELS detectors from Polymer Labs REFLEX IV MALDI-tof (+ robot) from BrukerREFLEX IV MALDI-tof (+ robot) from Bruker Capillary rheometerCapillary rheometer Precision WorkStation 620 from DellPrecision WorkStation 620 from Dell DSM micro mixerDSM micro mixer

P4 Associated Equipment Photo-Gonio-Diffusometer Static Light Scattering instrument (SOFICA)Photo-Gonio-Diffusometer Static Light Scattering instrument (SOFICA) Hot press for sample mouldingHot press for sample moulding Mini-extruderMini-extruder Glove boxesGlove boxes Several balancesSeveral balances On- and off-line data processingOn- and off-line data processing

Staff Appointed to P4 Dr C.R. ( Substitute will arrive soon)Dr C.R. ( Substitute will arrive soon)  Chemistry and reaction engineering Dr Fan ShunjieDr Fan Shunjie  Modelling and optimisation of reactors Ms Carolina Galmes-MeerhoffMs Carolina Galmes-Meerhoff  PhD student; hyperbranched systems Mr Mark SadlerMr Mark Sadler  Technician

Working with P4 Mr Simon Gretton-WatsonMr Simon Gretton-Watson  EPSRC supported PhD student Mr Zulhafiz TajudinMr Zulhafiz Tajudin  MSc student Dr Laurent KellerDr Laurent Keller  Unilever-funded joint A.G.M Barrett/J.H.G Steinke project

Internal Organisation Overview of the project Interaction with industry Julia, Tony,Vernon, Costas Synthesis of new polymeric materials Reaction mechanisms studies, kinetic data Characterisation of molecular and end-user properties Carolina, Catherine, Joachim Design of new polymerisation processes Transfer from lab to pilot plant scale Carolina, Catherine, Esat Modelling and optimisation processes Process System Engineering Fan, Steven NMR expertise Polymer chemistry expertise Robert, Joachim Set up laboratory day running and maintenance equipment Mark, Simon

Management Struture of P4 Steering GroupSteering Group  Comprise of about 7 representatives of the following categories: Industry - incl. SMEsIndustry - incl. SMEs Funders – EPSRC and DTIFunders – EPSRC and DTI  Will meet half yearly Management GroupManagement Group  Comprises of the 7 academic staff EA, SA, AGMB, JSH, VCG, RVL, JHGSEA, SA, AGMB, JSH, VCG, RVL, JHGS  Meets monthly with the P4 staff present

Reporting Arrangements for P4 Monthly meetings of Management GroupMonthly meetings of Management Group  Technical reports  Operational reports  Discussion of progress  Plans for future work Half yearly progress report to the Steering GroupHalf yearly progress report to the Steering Group  Details of some technical aspects for discussion  Discussion of the next phase of work

Deliverables 4 Novel polymers at kg scale4 Novel polymers at kg scale Polymers made available for evaluation in academia and industryPolymers made available for evaluation in academia and industry Generic advances in reaction and reactor engineeringGeneric advances in reaction and reactor engineering Generic approaches to predictive modelling of reaction and reactor scale-upGeneric approaches to predictive modelling of reaction and reactor scale-up Trained MSci students (CEP course)Trained MSci students (CEP course) Trained PhD studentsTrained PhD students Trained Postdocs Industrial consortiumTrained Postdocs Industrial consortium

Opportunities through P4 State-of-the-Art polymer characterisation facilitiesState-of-the-Art polymer characterisation facilities Super-flexible and “dry” Mini Pilot PlantSuper-flexible and “dry” Mini Pilot Plant Modelling with in-house software packagesModelling with in-house software packages Expertise of P4 academicsExpertise of P4 academics Connections throughout ICConnections throughout IC

Initial Projects Have Started Hyperbranched aliphatic polyurethanesHyperbranched aliphatic polyurethanes  Kinetics, reaction parameter space, side reactions Hyperbranched PMMAHyperbranched PMMA  Viscosity regime, gel limit Syndiotactic PMMASyndiotactic PMMA  Small scale, bulk polymerisation Novel polymer beadsNovel polymer beads  Un-beaded performance in synthesis

Immediate Deliverables Hyperbranched aliphatic polyurethanesHyperbranched aliphatic polyurethanes  Initial macroscopic property profiles determined Hyperbranched PMMAHyperbranched PMMA  Kg batch of well-characterised polymer made available for testing Syndiotactic PMMASyndiotactic PMMA  Kg batch of highly stereoregulat polymer made available for testing Novel polymer beadsNovel polymer beads  Parameters for controlled bead formation established

Immediate Projects Timetable Hyperbranched aliphatic polyurethanesHyperbranched aliphatic polyurethanes  Kinetics, reaction parameter space, side reactions Hyperbranched PMMAHyperbranched PMMA  Viscosity regime, gel limit

So what can you do to participate in the future success of P4 ? EPSRC could provide…EPSRC could provide…  …further funding eventually for new “blue skies” work Industry could provide…Industry could provide…  …Problems with Polymers to work on together - “Partners not Providers”

Partnership Activities Already agreement with Sulzer to provide reactor time for interesting case studies.Already agreement with Sulzer to provide reactor time for interesting case studies. Rent equipment and/or staff and possibly software for proprietorial case studies.Rent equipment and/or staff and possibly software for proprietorial case studies. BUT, we prefer interesting problems which we work on together – for example Send staff to participate in joint case studiesSend staff to participate in joint case studies  expertise and technology transfer Fund PhDs or PDRAs for longer studiesFund PhDs or PDRAs for longer studies  expertise, technology and person power transfer

P4 – 24 months on Facility running well and routinelyFacility running well and routinely Core funding for maintenance of equipment and for technical support in placeCore funding for maintenance of equipment and for technical support in place Research group of about the current size with a number of PhD and MSc students attachedResearch group of about the current size with a number of PhD and MSc students attached Steering Group meeting half yearlySteering Group meeting half yearly Consortium of interested Industrial partners who wish to participate in and develop the generic activities of P4.Consortium of interested Industrial partners who wish to participate in and develop the generic activities of P4.