Physico-chemical aspects of polyethylene processing in an open mixer

There are many reactions susceptible to yield aldehydes and acids in polyethylene melts. It is β-scission of the alkoxy radicals formed on bimolecular hydroperoxide decomposition that is expected to be one of the main sources of the aldehydes that are formed at increasing rates in the early stages of polyethylene processing. Acid-catalyzed decomposition of allylic hydroperoxides is another source of substantial amounts of aldehydes. Formation and decomposition of α,γ- and α,β-di-hydroperoxides should yield acids. The activation energy estimated for these different processes is very large (about 57 kcal/mol) so that their contribution could be significant in the high temperature range only. This is different for the reaction of aldehydes with hydroperoxides to yield peroxy-hemiacetals. These intermediates can be expected mainly in the low temperature range where hydroperoxides are accumulating. Decomposition of the peroxy-hemiacetals gives acids as one of the main products. Free-radical induced oxidation of aldehydes is likely to yield peracids as far as oxygen addition is competitive with decarbonylation. The main problem is the transformation of the peracids into acids. The reaction with double bonds is expected to yield significantly more acids than thermal decomposition of peracids. If the last occurs, it will be followed mainly by decarboxylation. The overall activation energy for both processes of acid formation is negative (−18 to −20 kcal/mol). It is some combination of the various mechanisms examined that might account for the experimental activation energy for acid formation in the initial stages that is close to 18 kcal/mol.