The beneficial influence of ultrasound in the polymerization of ε-caprolactam to polyamide-6 (Nylon 6). Part I: Primary experimental results

ε-caprolactam (CL) polymerization to polyamide-6 (Nylon 6) was studied at different contents of water in CL (0.01–2 wt%), with or without ε-amino-caproic acid (ACA) as an activator, applying to the mixture an initial treatment of Ultrasound (US) (17.5–20 kHz) at low temperatures (70–110 °C) and for short times (max 10 min). It was verified that polymerization at 260 °C produces a polymer having a much higher molecular weight (MW) when US is applied with respect to silent (SIL) conditions i.e. without the use of ultrasound. This constitutes a “pre-sonication effect”. The ratio (MW)US/(MW)SIL is inversely proportional to the initial content of water in CL. The action of US converts CL at very low temperatures (70–110 °C) and water content, in comparison with silent conditions where CL was unconverted.Optimized conditions are studied with respect to nature and pressure of gas inside the reactor, temperature, time and frequency of US irradiation, energy consumption and nature of activator.