Enhancing Reactive Microemulsion Processes: Dynamic Optimization and Cyclic Semibatch Operation for the Reductive Amination of Undecanal in a Mini-Plant

IF 3.8 3区 工程技术 Q2 ENGINEERING, CHEMICAL
Karsten Duch, Volodymyr Kozachynskyi, Karsten H. G. Rätze, Markus Illner, Kai Sundmacher, Jens-Uwe Repke
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Abstract

Achieving the maximum production rate of a chemical component in a process requires an optimal process design and operating strategy. One possible approach toward this goal is the elementary process function (EPF) optimization where the optimal temperature, pressure, and mass flow profiles for a Lagrangian fluid element are determined. In the current study, the EPF methodology is applied to the reductive amination of long-chain aldehydes in microemulsion systems (MES) to maximize the reaction performance. These solvent systems are a multiphase green chemistry approach to combine highly selective homogeneous catalysis with excellent catalyst retention using a water phase. For the reductive amination in MES, a cyclic semibatch operation is selected as the best approximation of the optimal EPF trajectories. This new process concept is implemented in a modular mini-plant, and successful validation of the optimization results is achieved for 19 consecutive semibatch reactions during a 125 h mini-plant campaign. The yield (43.8 ± 3.3) %, selectivity (64.3 ± 5.4) %, and conversion (68.0 ± 3.4) % are higher than those achieved in a previous mini-plant operation using a CSTR. Especially, the strong increase in selectivity, achieved through suppression of side product formation, proves that the EPF calculation can lead to a better process design and operating strategy. 99.1% of the catalyst entering the settler is recycled to the reactor, and the reaction performance remains constant for 125 h without requiring additional catalyst. This excellent catalyst retention and long-term stability support the results of previous studies, which outline the large potential of microemulsion systems as reaction media for homogeneous catalysis and their readiness for process implementations.

Abstract Image

强化反应性微乳液工艺:小型装置中十一醛还原胺化的动态优化和循环半批操作
在一个过程中实现化学成分的最大生产率需要一个最佳的过程设计和操作策略。实现这一目标的一种可能方法是基本过程函数(EPF)优化,其中确定拉格朗日流体单元的最佳温度、压力和质量流量分布。在目前的研究中,EPF方法被应用于微乳液体系(MES)中长链醛的还原胺化,以最大限度地提高反应性能。这些溶剂系统是一种多相绿色化学方法,结合了高选择性均相催化和优异的催化剂保留使用水相。对于MES中的还原胺化,选择循环半批操作作为最优EPF轨迹的最佳逼近。这个新的工艺概念在一个模块化的小型装置中实施,并在125小时的小型装置活动中成功验证了19个连续半批反应的优化结果。产率(43.8±3.3)%,选择性(64.3±5.4)%,转化率(68.0±3.4)%均高于之前使用CSTR的小型装置。特别是,通过抑制副产物形成而实现的选择性的大幅增加,证明了EPF计算可以导致更好的工艺设计和操作策略。进入沉淀池的99.1%的催化剂被回收到反应器中,在125 h内反应性能保持不变,无需额外添加催化剂。这种优异的催化剂保留率和长期稳定性支持了先前的研究结果,这些研究概述了微乳液体系作为均相催化反应介质的巨大潜力,以及它们对工艺实施的准备。
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来源期刊
Industrial & Engineering Chemistry Research
Industrial & Engineering Chemistry Research 工程技术-工程:化工
CiteScore
7.40
自引率
7.10%
发文量
1467
审稿时长
2.8 months
期刊介绍: ndustrial & Engineering Chemistry, with variations in title and format, has been published since 1909 by the American Chemical Society. Industrial & Engineering Chemistry Research is a weekly publication that reports industrial and academic research in the broad fields of applied chemistry and chemical engineering with special focus on fundamentals, processes, and products.
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