CA1114987A

CA1114987A - Resins

Info

Publication number: CA1114987A
Application number: CA305,455A
Authority: CA
Inventors: Thomas J. Howell
Original assignee: Rohm and Haas Co
Current assignee: Rohm and Haas Co
Priority date: 1977-06-27
Filing date: 1978-06-14
Publication date: 1981-12-22
Also published as: AU3745278A; IN149312B; JPS6414206A; DE2827475C2; AR228836A1; JPS627921B2; NL7806892A; ZA783340B; DE2827475A1; FR2396027A1; JPS5411984A; AU521552B2; ES471391A1; FR2396027B1; IT7868500A0; BE868487A; BR7804015A; GB1602064A; IT1111628B

Abstract

Abstract of the Disclosure Ion exchange resins having improved physical stability and perfect bead count are prepared by a free-radical catalyzed polymerization of a monomer mixture util-izing certain peroxyester and peroxydicarbonate catalysts, followed by functionalizing the so prepared polymer.

Description

1~14~ ~

This invention is directed to ion exchange resins of exceptional physical strength and form and method of preparing the same. More specifically, superior ion exchange resins are prepared by utilizing as polymerization catalysts a specific group of peroxyester and peroxydicar-bonate catalysts in the polymerization of monomers to form ion exchange beads.
The techniques of preparing crosslinked vinyl copolymers in bead form (as precursors for conversion into ion exchange resins) by free-radical catalyzed polymer-ization of the monomer mixture in aqueous dispersion are well known. The term "crosslinked vinyl copolymer" and the like is used for the sake of brevity herein to signify coply-mers of a major proportion, e.g., from 50 upwards to about 99.5 mole percent, preferably 80 to 99%, of a monovinyl monomer, for example, monovinyl aromatic monomers, e.g., styrene, vinyl, toluene, vinyl naphthalene, ethyl vinyl benzene, vinyl chlorobenzene, chloromethyl styrene, and the like, and esters of acrylic and methacrylic acid, e.g., methyl acrylate, ethyl acrylate, propyl acrylate, isopropyl acrylate, butyl acrylate, tert-butyl acrylate, ethyl hexyl acrylate, cyclohexyl acrylate, isobornyl acrylate, benzyl acrylate, phenyl acrylate, alkyl phenyl acrylate, ethoxymethyl acrylate, ethoxypropyl acrylate, propoxypropyl acrylate, ethoxyphenyl acrylate, ethoxybenzyl acrylate, ethoxycyclohexylacrylate, and the corresponding esters of methacrylic acid, with a minor proportion, e.g., of from about 0.5 up to 50 mole percent, preferably 1 to 20% of polyvinyl compounds having at least two active vinyl groups polymerizable with the afore-said monovinyl monomer to form a crosslinked, insoluble, 1~14~

infusible copolymer, said polyvinyl compounds being, for example, divinyl benzene, trimethylolpropane trimethacrylate, ethylene glycol dimethacrylate, divinyl toluene, trivinyl benzene, divinyl chlorobenzene, diallyl phthalate, divinylpyridine, divinylnaphthalene, ethylene glycol di-acrylate, neopentyl glycol dimethacrylate, diethylene glycol divinylether, bisphenol-A-dimethacrylate, pentaerythri-tol tetra- and trimethacrylates, divinylxylene, divinyl-ethylbenzene, divinyl sulfone, divinyl ketone, divinyl sul-fide, allyl acrylate, diallyl maleate, diallyl fumarate, diallyl succinate, diallyl carbonate, diallyl malonate, diallyl oxalate, diallyl adipate, diallyl sebacate, divinyl sebacate, diallyl tartrate, diallyl silicate, triallyl tri-carballylate, triallyl aconitate, triallyl citrate, triallyl phosphate, N,N'-methylenediacrylamide, N,NI-methylene dimeth-acrylamide, N,N'-ethylene-diacrylamide, trivinyl naphthalene, polyvinyl anthracenes and the polyallyl and polyvinyl ethers of glycol, glycerol, pentaerythritol, resorcinol and the mono-thio and dithio derivatives of glycols. The copolymer may -: -2Q also have incorporated therein polymerized units of up to - about 5 mole ~ of other vinyl monomers which do not affect the basic nature of the resin matrix, for example methyl acry- ~:;
late, acrylonitrile, butadiene and others known in the art.
The conventional conditions of polymerization used heretofore lead to crosslinked vinyl copolymers, which, when converted to ion exchange resins by attachment of ; functional groups thereto, have certain operational deficien-- cies resulting from physical weaknesses.
: The practice of the present invention yields ion exchange resins in which the polymer beads have greater mechanical strength, improved perfect bead count, and increased resistance to swelling pressures which are pro-duced within a bead during acid/base cycling (i.e., osmotic shock). The greater mechanical strength of the beads mani-fests itself in improved resistance to physical breakdown from external forces such as weight of the resin column bed, high fluid flows and backwashing. Thus, the physically stronger ion exchange resins embodied herein are especially useful in treating fluid streams of high flow rates, for example, condensate polishing applications in which resins of lesser quality are prone to mechanical breakdown and short ` life spans.
In copending Canadian Patent Applications, Serial Nos.
296,359 (Dales) and 303,589 (Howell et al) filed February 6, 1978 and May 17, 1978, respectively, it has been proposed to improve ion exchange resin quality by means of controlling the oxygen content of the monomer mixture during polymerization and/or the addition of a "reaction modifier"
to the monomer mixture. The teachings of these copending Canadian applications may be utilized in combination with the present invention.
The present invention resides in the finding that a particular group of peroxy catalysts, not heretofore known to have advantages in the manufacture of ion exchange polymers, produce a polymer which, when functionalized, is substan-~ tially and unexpectedly superior to corresponding materials - available heretofore. The catalysts which yield these advan-tages may be characterized generally as peroxyesters and peroxydicarbonates. The peroxyesters include the alkyl esters X

Or peroxycarboxylic acids and the alkylene bis(es~ers) .Or peroxycarboxylic aclds, which peroxyesters fall within the general rormula:

o ( Rl-C-O-O ) XR2 wherein Rl is a branched alkyl o~ 3 to 12 carbon atoms and having a secondary or tertiary carbon linked to the carbonyl.
group;
x is a positive integer having a value of 1 or 2, and when x is 1, R2 is a branched alkyl radical containing a .
tertiary carbon attached to the oxygen, that is:

C--R ,' ' 1 ~ :

wherein R',.R" and R"' are independently selected from linear or branched lower alkyl, and when x is 2, R2 is an alkylene .
. or aralkylene group, in either case terminating in tertiary 1 carbons attached to the oxygen, that is~
R' R' ---C R"' - C -- R" R"
wherein R' and R" are as defined above and R"' is a phenylene or lower alkylene group.
The peroxyester catalysts are presently available 20 commercially under the trademark "Lucidol" (Lucidol Division,) - Pennwalt Corporation) and are recommended ror vinyl polymer-izations.
The peroxydicarbonate catalysts useful by the pre-sent invention fall within the general formula .. ,`~~` ~
,, ,~

~4~

o o Y--OC--O--O--C O- Z

wherein Y and Z are independently selected from lower alkyl, cycloalkyl, alkyl-substituted cycloalkyl, and aralkyl. These materials are available commercially from Lucidol Division, Pennwalt Corporation under the tradenark "Iupersol", and N~y Chemical Corporation under the trademark "Percadox".
A preferred group of peroxyester catalysts include t-butyl peroctoate, t-butyl peroxy-2-ethyl-hexanoate, t-butyl peroxyisobutyrate, t-butyl peroxyneodecanoate, t-amyl peroctoate, and 2,5-dimethyl-2,5-bis(2-ethyl-hexanoylperoxy)-hexane.
; A preferred group of peroxydicarbonate catalysts include, Di(4-t-butylcyclohexyl)peroxydicarbonate, D (sec-butyl)peroxydicarbonate, Di(2-ethylhexyl)peroxydicarbonate, Dicetyl peroxydicarbonate, and Dicyclohexyl peroxydlcarbonate.
In accordance with this invention, the vinyl - monomer, crosslinking monomer and any other optional monomer or monomers, are polymerized in an aqueous dispersion con-taining the peroxy catalyst (alternatively "free radical initiator") and additionally, if desired, oxygen and~or a "reaction n~difier" as disclosed in the copending Canadian appli-cations mentioned supra. Generally, from about 0.1% to ~ about 2.0% Or catalyst by weight Or the monomer mixture is -- required to obtain the benefits of the invention, with the preferred amount being from 0.3% t~ 1.0~1 by weignt ~he monomer mixture. The methods Or polymerization utilized by the invention does not generally depart from the well known methods available heretofore for m~nufacture of ~4 ~_ ~

ion exchange polymers and resins.
The polymerization is normally carried out at temperatures ranging from about 30C to about 90C, prefer-- ably 45C to 80C and even more preferably 50C to 75C.
In a preferred embodiment, it is desirable to employ lower temperatures of reaction in the initial stages of polymeriza-tion, that is until at least about 50%, preferably 75% or more, of the monomers in the dispersion are reacted. The above-stated temperatures are for the initial stages of polymerization; during final stages of polymerization the temperature is desirably raised 20C-30C above the temper-ature used for the initial stages. As~taught in the copending Canadian pabent applications mentioned supra, it is possible bo operate at temperatures 15-35C below temperatures normally ~
15 used in prior art methods. When ~perating at lower temper- ~ ~-atures, e.g., 30C-60C using catalysts of the invention ("Percadox" type) it may be desirable to emp~y a second so-called - "chaser catalyst" whlch is active at higher temperatures, e.g.~ 75-100C, in order to achieve higher yields of crosslinked vinyl polymer, for example, from about 0.05 to - 0.1% based on monomer weight of such initiators as benzoyl peroxide, t-butyl peroctoate, t-butyl peroxyisobutyrate, and the like.
The aqueous media in which the polymerization is conducted in dispersion form will contain minor amounts of the conventional suspension additives, that is, dispersants such as xanthan gum (biosynthetic polysaccaride), poly-(diallyl dimethyl ammonium chloride), polyacrylic acid (and salts), polyacrylamide, magnesium silicate, and hydrolyzed poly(styrene-maleic anhydride); protective colloids such as *Trademark 7 .. ~

~4~-7 carboxymethyl cellulose, hydroxyalkyl cellulose, rncthyl cellulose, polyvinyl alcohol, gelatin, and alginates;
buffering aids such as phosphate and borate salts; and pH control chemicals such as sodium hydroxide and sodium carbonate.
The crosslinked, high-molecular weight copolymers are recovered from the reactor as hard, discrete beads of particle size within the range of about 0.02 to 2 mm, average particle size being on the order of 0.2 to 1 mm.
These copolymers are converted to ion exchange resins by attachment Or functional groups thereto by conventional means, such as functional groups including sulfonamide, trialkylamino, tetraalkyl ammonium, carboxyl, carboxylate, sulfonic, sulfonate, hydroxyalkyl ammonium, iminodiacetate, amine oxide, phosphonate, and others known in the art.
Functionalizing reactions which may be performed on vinyl aromatic copolymers to produce ion exchange resins are exemplified by sulfonation with concentrated sulfuric acid, chlorosulfonation with chlorosulfonic acid followed by amination, reaction with sulfuryl chloride or thionyl chloride -followed by amination, and chloromethylation followed by amination. Typical functionalizing reactions on (vinyl) ~ acrylic copolymers include hydrolysis to acrylic acid resins, - amidolysis, transesterification, and the like. Ion exchange resins may be further delineated by the types: strong acid cation, i.e., containing the groupings sulfonic (-SO3~1) or sulfonate (-SO3M, where M is usually an alkali metal ion);
weak acid cation, i.e., containing the groupings carboxyl (CO2H) or carboxylate (-CO~M, where M is usually an al'~ali metal ion); strong base anion, i.e., containing the te ra-1~, ;4r )~

alkyl ammonium groupings: -NR3X, where R is an alkyl or ~hydroxy alkyl group and X ls usually chloride or hydroxide;
and weak base anion, i.e., containing a trialkylamino group, -NR2, where R is an alkyl or hydroxyalkyl group.
The improvements in the properties of the resins produced according to this invention are not evident until .
the crosslinked copolymers are converted to ion exchange resins by the attachment Or the aforesaid functional groups.
The enhanced physical strength of these latter resins is --apparent from their resistance to crushing which is conven-iently measured on the Chatillon instrument, as well as by visual inspection before and after use in ion exchange .
applications. For example, strong acid, styrene-type resins produced in accordance with the preferred method of this invention frequently exhibit Chat-illon values in the range Or about 1000 to about 5000 gm, force per bead, in contrast to resins derived from copolymers prepared by prior art polymerization methods which have Chatillon values in the range Or about 50 to 500 gm/bead. Similarly, strong base styrene-type resins of the invention frequently exhibit Chatillon values o~ about 500 to 1500 in contrast to resins derived from copolymers prepared by prior art methods which ` - have Chatillon values of 25 to 400.
The process of the invention is clarified by the following illustrative examples which are not to be construed as limitative thereo~

Example 1 . . ~
-` The polymerization reactor is a two liter, three neck, round bottom flask equipped with a two blade paddle stirrer, 3 thermometer, condenser, heating mantle with temperature ., ~ . .

controller al~d provision for sweeplng with an incrt gas.
Into this reactor is charged a monomer mixture consisting Or 500.4 g styrene and 85.6 g divinylbenzene, and 1.9 g t-butyl peroctoate. The head space is swept with nitrogen and the aqueous phase is then added: 510 g water, 20.1 g poly(diallyldimethyl ammonium chloride) dispersant, 1.6 g Or gelatin protective colloid, o.88 g boric acid, and sufficient 50% sodium hydroxide solution to maintain pH
between 10.0 and 10.5. The stirrer is started and the reaction mixture is heated from room temperature to 75C
over 45 minutes and held at this temperature for 4.0 hours.
Thereafter, the polymerization is "finished off" by holding the reaction mixture at 95 C for 1 hour. The copolymer beads are separated, washed and prepared for functionalization.
A strong acid resin may-be prepared from the copolymer of Example 1 by means of the following alternative ; procedures.
Sulfonation A
A portion of the copolymer beads as prepared above (110 g) is added to 600 g of 95% H2S04 is a one liter flask equipped with stirrer, condenser, dropping funnel, thermometer, caustic scrubber and heating means. Thirty nine grams of - ethylene dichloride (bead swelling agent) are added, and - the.suspension is heated from 30C to 130C over a three hour period. This is followed by a hydration procedure in which water is added to quench the product. The sulfonated - product is then washed to remove residual acid. The physical properties of the strong acid resin product are set forth in Table I, hereinafter.

~-Sulfonation E3 A portlon Or the copolymer beads as prepared in Example I above ( 50g) is added to 315 g Or 94% H2S04 in a one liter flask equipped with stirrer, condenser, dropping funnel, thermometer, caustic scrubber, and heating Means.
Thirty grams of ethylene dichloride (bead swelling agent) are added, and the suspension is heated to 60-65C where it is held for one hour. The mixture is then heated to 115C and held there for 4 hours. This is followed by a hydration - 10 step in which water is added to quench the product. The sulfonated product is then washed to remove residual acid.
0f the first eighteen specific examples herein, Examples 1, 2, 4-7, and 11-18 the copolymer products were ` functionalized by Sulfonation method "A", and the remaining Examples employed Sulfonation method "B".
Example 2 Using the same procedure set forth in Example 1, a copolymer ion exchange resin precursor was prepared from iden-~- tical starting materials in identical amounts. The properties of the product, after sulfonation are as given below in Table I.
Example 3 Following the procedure of Example 1, 254.5 g of styrene, 42.4 grams of divinylbenzene, 3.0 g methyl acrylate~
25 and 1. 5 g t-butyl perOctoate were charged to the reactor.

"I' The aqueous phase consisted of 270 g H20, 10.0 g poly(diallyl dimethyl ammonium chloride), o.8 g of gelatin protective colloid, 0.45 g boric acid and 50% NaOE~ solution to maintain the p~l between 10.0 and 10. 5. The reaction mixture was heated 30 to 75C for 2.7 hours, then 95c for an additional hour. The I

,, product was was~led and sulronated. The properties Or the resin are given below in Table I.
ExamPle 4 ~ollowing the procedure of Example l, 491.7g of styrene, 85.5 g of divinylbenzene, 8.8 g methyl acrylate, 0.51 g methylcyclopentadiene dimer, and 1.90 g t-butyl-peroctoate were charged to the reactor. The aqueous phase consi-sted of ~10.0 g H2O, 20.1 g of poly(diall~l dimethyl ammonium chloride), 1.6 g of gelatin protective colloid, 0.83 g boric acid and 50% NaOH solution to maintain the pH
between 10.0 and 10.5. The reaction mixture was heated to 75C for 4 hours and then 95C for an additional hour. The product was washed and sulfonated. The properties of the resin are given below in Table I.
Example 5 Following the procedure of Example l, 491.7 grams ~- of styrene, 85.5 grams of divinylbenzene, 8.8 g of methyl acrylate, 0.59 g methylcyclopentadiene dimer, and 1.90 g . of t-butylperoctoate were charged to the reactor. The aqueous phase consisted Or 510.0 g of H2O, 20.1 g poly(dially-l d~methyl ammonium chloride), 1.6 g gelatin protective colloid, o.88 g boric acid and sufficient 50% NaOH solution to main-tain the pH between 10.0 and 10.5. The reaction mixture was heated to 75C for 4 hours and 95C for an additional hour.
The product was washed and sulfonated. The properties of the resin are given below in Table I.
ExamPle 6 Following the procedure of Example 5, using the same organic and aqueous phases, a resin was prepared having the properties set forth in Table I.

i `7 Examp]c 7 .
~ `ollowing the procedure Or Example 1, but including the reaction modifier ~-methylstyrene dimer (0.59 g) and the initiator t-butyl peroctoate (1.9 g) a resin was prepared having the properties set forth in Table I.
Example 8 Following the procedure of Example 1, but including 3.0 g methyl acrylate, 1.5 g t-butyl peroctoate, and 0.3 g cycloheptatriene (reaction modifier), a resin was prepared having the properties set forth in Table I.
Example 9 Following the general procedure of Example 1, but including 3.0 g methyl acrylate, 1.5 g t-butyl peroctoate and 0.3 g norbornene (reaction modifier) a resin was pre-pared having the properties set forth in Table I.
Exampie 10 Following the general procedure of Example 1, butincluding 3.0 g methyl acrylate, 1.5 g t-butyl peroctoate and 0.3 g dicyclopentadiene (reaction modifier) a resin was prepared having the properties set forth in Table I.
- Example 11 Following the general procedure of Example 1, but including 8.8 g methyl acrylate, 0.29 g methylcyclopentadiene dimer (reaction modifier) and 2.64 g di-(4-t-butylcyclohexyl)-peroxydicarbonate (Percodox 16 - T.M.) a resin was prepared having the properties set forth in Table I. A blanket of 8% 2 in N2 was swept over the reaction mixture for 30 minutes. Also 0.59 sodium nitrite was used in the aqueous phase to prevent polymerization therein (also in Examples 12 and 13 which follow).

.,~ .

. ., .. .. ~ . .. ... . . ..

1~4C~ 7 Example 12 Following the general procedure Or Example 1, but including 8.8 g methyl acrylate, 0.29 g methylcyclo-pentadlene dimer, and 2.64 g di-(4-t-butylcyclohexyl)-peroxydicarbonate (initiator) in the organic phase a resinwas prepared. The initial polymerization was conducted at 57% for seven hours after which the temperature was raised to 95% for 1 hour. The properties Or the resin were as shown in Table I.
Example 13 Following the general procedure of Example 1, but -using 8.8 methyl acrylate and 2.64 g di-(4-t-butylcyclohexyl)-peroxydicarbonate (but no reaction modifier) and a reaction temperature of 56C for seven hours and 75C for two hours, a resin was prepared having the properties set forth in TabIe I.
- Example 14 Following the general procedure of Example 1, but using 1.9 g of 2,5-dimethyl-2,5-bis(2-ethylhexanoylperoxy)-hexane (initiator) and a reaction temperature of 70C for4 hours followed by 90C for 1 hour, a resin was prepared having the properties set forth in Table I.
- Example 15 , ; .
Following the general procedure of Example 1, but using 1.12 g t-butyl peroxyneodecanoate (initiator) an initial reaction temperature of 53-54C for 4.5 hours and 70C for 1 hour thereafter, a resin was prepared having the properties set forth in Table I.
The following examples illustrate the prior art method of preparation and products resultin& therefrom.
~-~ ~ ~ 4~ ~ 7 Example 16 Following the general procedure Or Example 1, using

2.20 gra~s of benzoyl perox..de (initiator) an ini'~ial reaction temperature of 75C for 4 hours and a final temperature Or 95C for 1 hour, a resin was prepared having the properties set forth in Table I.
Examples 17 and 18 Example 16 was repeated twice and the products : resulting had properties set forth in Table I.
. 10 The resins produced according to the foregoing examples were tested to determine the percentage whole bead count (%WB) percentage perfect bead count (%PB) the crushing strength of the beads (Chatillon test method) and the %
reduction of the perfect bead count arter repeated cycling in acid and base solutions (on accelerated usage test). All tests were conducted on thé resin after sulfonation.

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~-' . .
, ~4 ~ J

TABLE I
PHYSICAL P~OPERTIES OF RESI~S
% Reduction Example Chatillon in PB After No. %WB %PB _g./bead Cycling 2 98 92 lloo

3 99 95 1520 5*

4 loO 98 1610 6 - 8 99 98 1810 3*
9 99 95 1450 .2*
~0 99 98 l9oO 8~ -:~ 11 97 98 1770 - :
12 98 98 1400 . o 98 87 goo - - :
16 99 go 325 49 ` 17 99 91 335 52 *50 cycles with lN HCl and lN NaOH, all others have 100 cycles with lN HCl and O. 5N NaOH
Weak and strong base resins having improved ~rop- .. ;
25 erties may also be prepared in accordance with the present invention, substituting the well known methods for post-~- -functionalizing the copolymer resin to produce weak or strong anion exchange groups for the sulfonation method shown above.
A preferred method known in the art for functionalizing with 30 anion exchange groups involves chloromethylation followed by aminat~on.
Examples 19-20 ; Two styrene/divinylbenzene strong base resins were prepared followlng the general procedure Or Example 1 for the copolymer, and using conventional chloromethylation/
amination procedures to functionalize the copolymer. The copolymer of Example 19 utilized terpinolene as a reaction modifier and 2,6-dimethyl-2,4,6-octatriene was utilized for Example 20. Both copolymers utilized t-butyl peroctoate as the initiator. A control sample of a commercial strong base resin produced without reaction modifier and using a ~` conventional prior art initiator was produced for comparative purposes. The properties of the resins produced are set forth in Table II.
~` 15 TABLE II
` PROPERTIES OF STRONG BASE RESINS
F` "
Example Chatillion No. %WB %PB g./bead ` 20 20 100 99 750 -~ Control -~ (commercial strong base resin) 100 94 140 As used herein and in the appended claims the acid/base cycling test is conducted with 1 normal HCl and 0.5 normal NaOH at room temperature for 100 cycles, at approximately two cycles per hour.

.

',' '

Claims

What is Claimed is:

1. In the process of preparing hard, crosslinked discrete copolymer beads by the free-radical polymerization in an aqueous dispersion of a monomer mixture comprised of a major proportion of monovinyl monomer and a minor pro-portion of a crosslinking monomer having at least two active vinyl groups, the improvement which comprises con-ducting the polymerization reaction in the presence of a peroxy catalyst of the formula:
wherein R1 is a branched alkyl of 3 to 12 carbon atoms and having a secondary or tertiary carbon linked to the carbonyl group and x is a positive integer having a value of either 1 or 2 and when x is 1, R2 is a branched alkyl radical containing a tertiary carbon attached to the oxygen, and when X is 2, R2 is an alkylene or aralkylene group, in either case terminating in tertiary carbons attached to the oxygen, or of the formula:
wherein Y and Z are independently selected from lower alkyl, cycloalkyl, alkyl-substituted cycloalkyl and aralkyl.

2. The process of claim 1 wherein the peroxy catalyst is t-butyl peroctoate.

3. The process of claim 1 wherein the peroxy catalyst is t-butyl peroxyneodecanoate.

4. The process of claim 1 wherein the peroxy catalyst is 2,5-dimethyl-2,5-bis(2-ethylhexanoylperoxy)-hexane.

5. The process of claim 1 wherein the peroxy catalyst is di-(4-t-butylcyclohexyl)peroxydicarbonate.

6. The process of claim 1 wherein the peroxy catalyst is dicyclohexyl peroxydicarbonate.

7. The process of claim 1 wherein the polymeri-zation with the peroxy catalyst is conducted with oxygen in contact with the monomer mixture so that oxygen is absorbed by said monomer mixture at least until the polymerization reaches the gel point.

8. The process of claim 1 wherein the polymeri-zation with the peroxy catalyst is conducted with a modifier in admixture with the monomer mixture in a concentration of from about 0.01 to about 20 millimoles per mole of monomer, said modifier being an organic compound containing acetylenic or allylic unsaturation.

9. The process of claim 1 wherein the polymeri-zation with the peroxy catalyst is conducted with the oxygen addition of claim 7 and the modifier addition of claim 8.

10. Hard, crosslinked discrete ion exchange beads formed by the free-radical polymerization in an aqueous dispersion of a monovinyl monomer and a polyvinyl monomer followed by functionalization of the resulting copolymer to form ion exchange sites therein which have a perfect bead count of at least 90.0%, a Chatillion value of at least 500g/bead and capable of withstanding fifty cycles of alternating acid and base treatment without loss of more than 15.0% of the original perfect bead content.