Towards the sustainable production of methyl methacrylate: A comparative analysis of industrial chemical production processes using life cycle assessment methodology

Increasing environmental awareness has been a significant driving force for innovations and process improvements in different sectors and the field of chemistry is not an outlier. Innovating around industrial chemical processes in line with current environmental responsibilities is however no mean feat. One of such hard to overhaul process is the production of methyl methacrylate (MMA) commonly produced via the acetone cyanohydrin (ACH) process developed back in the 1930s. Different alternatives to the ACH process have emerged over the years and the Alpha Lucite process has been particularly promising with a combined plant capacity of 370,000 metric tonnes in Singapore and Saudi Arabia. This study applied Life Cycle Assessment methodology to conduct a comparative analysis between the ACH and Lucite processes with the aim of ascertaining the effect of applying principles of green chemistry as a process improvement tool on overall environmental impacts. A further comparison was made between the Lucite process and a lab-scale process that is further improvement on the former, also based on green chemistry principles. Results showed that the Lucite process has higher impacts on resource scarcity and ecosystem health whereas the ACH process has higher impacts on human health. On the other hand, compared to the Lucite process the lab-scale process has higher impacts in both the ecosystem and human health categories with lower impacts only in the resource scarcity category. It was observed that the benefits of process improvements with green chemistry principles might not be apparent in some categories due to some limitations of the methodology. Process contribution analysis was also performed and it revealed that the contribution of energy is significant, therefore a sensitivity analysis with different energy scenarios was performed. An uncertainty analysis using Monte Carlo analysis was also performed to validate the consistency of the results in each of the comparisons.

Polymer-liquid crystal interface: a molecular dynamics study

Liquid crystals (LCs) are an interesting class of soft condensed matter systems characterized by an unusual combination of fluidity and long-range order, mainly known for their applications in displays (LCDs). However, the interest in LC continues to grow pushed by their application in new technologies in medicine, optical imaging, micro and nano technologies etc. In LCDs uniaxial alignment of LCs is mainly achieved by a rubbing process. During this treatment, the surfaces of polymer coated display substrates are rubbed in one direction by a rotating cylinder covered with a rubbing cloth. Basically, LC alignment involves two possible aligning directions: uniaxial planar (homogeneous) and vertical (homeotropic) to the display substrate. An interesting unresolved question concerning LCs regards the origin of their alignment on rubbed surfaces, and in particular on the polymeric ones used in the display industry. Most studies have shown that LCs on the surface of the rubbed polymer film layer are lying parallel to the rubbing direction. In these systems, micrometric grooves are generated on the film surface along the rubbing direction and also the polymer chains are stretched in this direction. Both the parallel aligned microgrooves and the polymer chains at the film surface may play a role in the LC alignment and it is not easy to quantify the effect of each contribution. The work described in this thesis is an attempt to find new microscopic evidences on the origin of LC alignment on polymeric surfaces through molecular dynamics (MD) simulations, which allow the investigation of the phenomenon with atomic detail. The importance of the arrangement of the polymeric chains in LCs alignment was studied by performing MD simulations of a thin film of a typical nematic LC, 4-cyano-4’-pentylbiphenyl (5CB), in contact with two different polymers: poly(methyl methacrylate)(PMMA) and polystyrene (PS). At least four factors are believed to influence the LC alignment: 1. the interactions of LCs with the backbone vinyl chains; 2. the interactions of LCs with the oriented side groups; 3. the anisotropic interactions of LCs with nanometric grooves; 4. the presence of static surface charges. Here we exclude the effect of microgrooves and of static surface charges from our virtual experiment, by using flat and neutral polymer surfaces, with the aim of isolating the chemical driving factors influencing the alignment of LC phases on polymeric surfaces.

Studio approfondito di processi post-polimerizzazione del poli(glicidil metacrilato)

The reactivty of poly(glycidyl methacrylate), obtained by RAFT controlled radical polymerization, has been investigated with a nucelophilic agent, such as morpholine, in various aprotic polar solvents in order to optimize the reaction (time and nucleophile excess). A strong interaction between polymer and solvent, gained by hydrogen bonds, during the process has proved to be essential in order to lower the reaction time and the nucelophilic agent excess. Dissimilar behaviors have been detected by GPC analysis due to the reactivity of the sulfhydryl formed during the RAFT's aminolysis. The various solvents lead to conditions in which different inter and intra-chain associations occur; the result is the formation of dimers, trimers and tetramers (to a less extent) in the first case, and cyclical structures in the second one. The reactivity of the hydroxy group, formed during the ring opening reaction, has been further investigated in order to link isothiocyanate-functionalized fluorescent marker along the polymeric chain.

Preparation and characterization of grafted nonwoven membranes for bioseparations

Protein purification plays a crucial role in biotechnology and biomanufacturing, where downstream unit operations account for 40%-80% of the overall costs. To overcome this issue, companies strive to simplify the separation process by reducing the number of steps and replacing expensive separation devices. In this context, commercially available polybutylene terephthalate (PBT) melt-blown nonwoven membranes have been developed as a novel disposable membrane chromatography support. The PBT nonwoven membrane is able to capture products and reduce contaminants by ion exchange chromatography. The PBT nonwoven membrane was modified by grafting a poly(glycidyl methacrylate) (GMA) layer by either photo-induced graft polymerization or heat induced graft polymerization. The epoxy groups of GMA monomer were subsequently converted into cation and anion exchangers by reaction with either sulfonic acid groups or diethylamine (DEA), respectively. Several parameters of the procedure were studied, especially the effect of (i) % weight gain and (ii) ligand density on the static protein binding capacity. Bovine Serum Albumin (BSA) and human Immunoglobulin G (hIgG) were utilized as model proteins in the anion and cation exchange studies. The performance of ion exchange PBT nonwovens by HIG was evaluated under flow conditions. The anion- and cation- exchange HIG PBT nonwovens were evaluated for their ability to selectively adsorb and elute BSA or hIgG from a mixture of proteins. Cation exchange nonwovens were not able to reach a good protein separation, whereas anion exchange HIG nonwovens were able to absorb and elute BSA with very high value of purity and yield, in only one step of purification.