Optimizing the Conditions of Cationic Polyacrylamide Inverse Emulsion Synthesis Reaction to Obtain High–Molecular–Weight Polymers

Cationic polyacrylamide (CPAM) emulsifier is widely applied in the wastewater treatment industry, mining industry, paper industry, cosmetic chemistry, etc. However, optimization of input parameters in the synthesis of CPAM by using the traditional approach (i.e., changing one factor while leaving the others fixed at a particular set of conditions) would require a long time and a high cost of input materials. Onsite mass production of CPAM requires fast optimization of input parameters (i.e., stirring speed, reaction temperature and time, the amount of initiator, etc.) to minimize the production cost of specific–molecular–weight CPAM. Therefore, in this study, we synthesized CPAM using reverse emulsion copolymerization, and proposed response surface models for predicting the average molecular weight and reaction yield based on those input parameters. This study offers a time–saving tool for onsite mass production of specific–molecular–weight CPAM. Based on our response surface models, we obtained the optimal conditions for the synthesis of CPAM emulsions, which yielded medium–molecular–weight polymers and high conversion, with a reaction temperature of 60–62 °C, stirring speed of 2500–2600 rpm, and reaction time of 7 h. Quadratic models showed a good fit for predicting molecular weight (Adj.R(2) = 0.9888, coefficient of variation = 2.08%) and reaction yield (Adj.R(2) = 0.9982, coefficient of variation = 0.50%). The models suggested by our study would benefit the cost–minimization of CPAM mass production, where one could find optimal conditions for synthesizing different molecular weights of CPAM more quickly than via the traditional approach.