A mathematical model was developed to predict the drying mechanism of semicrystalline polymers involving multiple solvents. Since drying of semicrystalline polymers can be accompanied by changes in polymer degree of crystallinity, the model integrates crystallization kinetics and the Vrentas -Duda diffusion model to provide a better understanding of the mechanism. The model considers the effect of external conditions such as temperature, film shrinkage and diffusion and evaporation of multiple solvents during drying. Poly(vinyl alcohol) (PVA)/water/methanol was chosen as a test system. The drying kinetics of PVA films swollen in water and methanol were investigated using gravimetric techniques. The model predicts that higher temperatures, lower film thicknesses and lower methanol to water ratios increase the drying rate. The model predictions were compared with experimental data and showed good agreement. q

The effect of glassy skin formation on the drying of semicrystalline polymers was investigated with a comprehensive mathematical model developed for multicomponent systems. Polymers with high glass-transition temperatures can become rubbery at room temperature under the influence of solvents. As the solvents are removed from the polymer, a glassy skin can form and continue to develop. The model takes into account the effects of diffusion-induced polymer crystallization as well as glassy-rubbery transitions on the overall solvent content and polymer crystallinity. A Vrentas-Duda free-volume-based diffusion scheme and crystallization kinetics were used in our model. The polymer-solvent system chosen was a poly(vinyl alcohol) (PVA)-water-methanol system. The drying kinetics of PVA films were obtained by gravimetric methods with swollen films with known water/methanol concentrations. The overall drying behaviors of the polymer system determined by our model and experimental methods were compared and found to match well.

Crystallization of semicrystalline polymer films during drying has a significant effect on the rate of solvent removal. Understanding and controlling the crystallization kinetics is important in controlling residual solvent levels and drying kinetics. The degree of crystallinity of the poly(vinyl alcohol) films during multicomponent drying was investigated using Fourier transform infrared spectroscopy (FTIR). The 1141 cm À1 band is sensitive to the degree of crystallinity of the polymer and the growth of intensity of this band was monitored as drying progressed. The results from the FTIR studies were comparable to the results obtained from differential scanning calorimetry. Studies were conducted to test the effect of initial solvent composition (water-methanol mixture), drying temperature, and polymer molecular weight on the rate of crystallization and the final crystallinity of the films. An increase in initial methanol composition increased the crystallization rate but did not affect the final degree of crystallinity. An increase in drying temperature and decrease in polymer molecular weight increased the rate of crystallization as well as the final degree of crystallinity. Based on the experimental data, rate constants for crystallization kinetics were extracted from our previously developed model based on free volume theory. The experimental data and the simulation results showed good agreement. The ability of the free volume theory to illustrate the crystallization behavior validated the model and improved its capability.

The development of a glassy skin in multicomponent semicrystalline polymer systems limits the diffusion of solvents out of the system and increases residual solvent levels. Based on the results of a mathematical model that we had previously developed, we have proposed a multi-zone drying scheme aimed at lowering the residual solvent levels by taking into account the effect of interactions between the various solvents as predicted by the model. This article focuses on the application of this model to develop optimal drying schemes and to verify the effectiveness of these predictions using experimental techniques. The mathematical model developed previously to study the diffusion of multiple solvents and changes in the crystallinity of semicrystalline polymer systems during drying incorporates many features including Vrentas-Duda diffusion theory, solvent-induced crystallization kinetics, as well as glass transition effects and skinning of the film. The multi-zone drying system was developed by varying the drying temperature in each zone as well as changing the partial pressure of individual solvents during the drying process. The effectiveness of the multizone drying schemes predicted by the model was validated experimentally using thermogravimetric methods. The polymer-solvent system chosen was a poly(vinyl alcohol)-water-methanol system. Our experimental data suggested that the multi-zone drying schemes were superior to a single-zone drying system through direct comparison. Further examination of the mathematical model yielded individual solvent profiles and these data reaffirmed our conclusions that a multi-zone drying scheme has the ability to reduce the effect of solvent trapping and thus lower the overall residual solvent content.

Introduction Mathematical Modeling Experimental Results and Discussion Conclusions Acknowledgements References and Notes Tables and Figures CHAPTER 3. Understanding the Effect of Skin Formation on the Removal of Solvents from Semicrystalline Polymers Abstract Introduction Theory Experimental Results and Discussion Conclusions Acknowledgements References and Notes v iv CHAPTER 4. A Study of Crystallization of Poly(vinyl alcohol) During Solvent Removal: Infrared Characterization and Mathematical Modeling Abstract Introduction Experimental Mathematical Model Results and Discussion Conclusions Acknowledgements References Tables and Figures CHAPTER 5. Investigation of the Effectiveness of Multi-zone Drying Schemes in Lowering the Residual Solvent Content During Multicomponent Drying of Semicrystalline Polymers Abstract Introduction Experimental Mathematical Modeling Results and Discussion Conclusions Acknowledgements References Tables and Figures CHAPTER 6. Conclusions and Future Directions