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Open-air emulsion polymerisation via semi bio-Fenton route
Researchers have demonstrated a fast emulsion polymerisation process that runs successfully in an open-to-air environment. By combining glucose oxidase with Fenton chemistry, the so-called “semi bio-Fenton” approach achieves full monomer conversion within minutes, opening new opportunities for coatings and cosmetic applications.
Radical and emulsion polymerisation processes are widely used in polymer synthesis for their versatility and simplicity. However, both academia and industry are looking for open-to-air solutions to improve cost and process efficiency. The newly developed method uses glucose oxidase (GOx), an enzyme that depletes oxygen while converting D-glucose to D-glucono-δ-lactone and generating hydrogen peroxide (H₂O₂). The H₂O₂ then produces hydroxyl radicals via the Fenton reaction, initiating polymerisation even in the presence of atmospheric oxygen.
This combination of Fenton chemistry and enzymatic oxygen consumption, referred to as “semi bio-Fenton” polymerisation, enables polymer formation without conventional deoxygenation steps. The researchers focused primarily on butyl methacrylate (BMA), examining the influence of surfactant, catalyst and monomer concentration on reaction kinetics, molecular weight and dispersity.
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Rapid conversion and broad monomer suitability
Increasing the surfactant concentration from 1 to 2.5 wt% significantly accelerated the reaction rate. Full monomer conversion was achieved within five minutes for 5 % v/v of monomer, and even at a higher concentration of 20 % v/v, only about ten minutes were required for complete conversion under optimised conditions. These results highlight the efficiency of the process compared with conventional emulsion polymerisation routes that require inert atmospheres.
The approach was also validated for methyl methacrylate (MMA) and vinyl acetate (VAc), and successfully applied in copolymerisation as well as in situ emulsion polymerisation combined with coating application. The findings suggest a viable alternative for emulsion polymerisation in applications where deoxygenation or conventional initiation systems are impractical or prohibited, such as coatings and cosmetic formulations.
Source: Kalita, U. et al., A fast emulsion polymerization in an open-to-air environment. Polymer Chemistry (2026).
