Link to original published version: http: //dx.doi.org/10.1016/j.seppur.2015.12.023 Citation: Aqar DY, Rahmanian N and Mujtaba IM (2016) Methyl lactate synthesis using batch reactive distillation: Operational challenges and strategy for enhanced performance. Separation and Purification . AbstractBatch reactive distillation is well known for improved conversion and separation of desired reaction products. However, for a number of reactions, the distillation can separate the reactants depending on their boiling points of them and thus not only reduces the benefit of the reactive distillation but also offers operational challenges for keeping the reactants together. Methyl lactate (ML) synthesis via the esterification of lactic acid (LA) with methanol in a reactive distillation falls into this category and perhaps that is why this process has not been explored in the past. The boiling points of the reactants (LA, methanol) are about 490 K and 337 K while those of the products (ML, water) are 417 K and 373 K respectively. Clearly in a conventional reactive distillation (batch or continuous) methanol will be separated from the LA and will reduce the conversion of LA to ML significantly.Here, first the limitations of the use of conventional batch distillation column (CBD) for the synthesis of ML is investigated in detail and a semi-batch reactive distillation (SBD) configuration is studied in detail where LA is the limiting reactant and methanol is continuously fed in excess in the reboiler allowing the reactants to be together for a longer period. However, this poses an operational challenge that the column has to be carefully controlled to avoid overflow of the reboiler at any time of the operation. In this work, the performance of SBD for the synthesis of ML is evaluated using model based optimization in which operational constraints are embedded. The results clearly demonstrate the viability of the system for the synthesis of ML.

Although batch reactive distillation process outperforms traditional reactor-distillation processes due to simultaneous reaction and separation of products for many reaction systems, synthesis of Methyl lactate (ML) through esterification of lactic acid (LA) with methanol in such process is very challenging due to difficulty of keeping the reactants together when one of the reactants (in this case methanol) has the lowest boiling point than the reaction products. To overcome this challenge, two novel reactive distillation column configurations are proposed in this work and are investigated in detail. These are: (1) integrated conventional batch distillation column (i-CBD) with recycled methanol and (2) integrated semi-batch and conventional batch distillation columns (i-SBD) with methanol recovery and recycle.Performances of each of these configurations are evaluated in terms of profitability for a defined separation task. In i-SBD column, an additional constraint is included to avoid overflow of the reboiler due to continuous feeding of methanol into the reboiler as the reboiler is initially charged to its maximum capacity. This study clearly indicates that both integrated column configurations outperform the traditional column configurations (batch or semi-batch) in terms of batch time, energy consumption, conversion of LA to ML, and the achievable profit.

Catalysts play a vital role in petroleum and chemical reactions. Intensified concerns for cleaner air with strict environmental regulations on sulfur content in addition to meet economic requirements have generated significant interests for the development of more efficient and innovative oxidative catalysts recently. In this study, a novel homemade nano catalyst (manganese oxide (MnO2) over tin (IV) oxide (SnO2)) was used for the first time as an effective catalyst in removing dibenzothiophene (DBT) from kerosene fuel using hydrogen peroxide (H2O2) as oxidant in catalytic oxidative-extractive desulfurization process (OEDS). The catalyst was prepared by impregnation method with various amount of MnO2 loaded on SnO2. The oxidation step was carried out at different operating parameters such as reaction temperature and reaction time in batch reactor. The extractive desulfurization step was performed by using acetonitrile as solvent under several operating conditions (agitation speed and mixing time). The activity of MnO2/SnO2 catalyst in removing various sulfur compounds from kerosene fuel at the best operating conditions was investigated in this work. The results of the catalyst characterization proved that a high dispersion of MnO2 over the SnO2 was obtained. The experiments showed that the highest DBT and various sulfur compounds removal efficiency from kerosene fuel under the best operating conditions (oxidation: 5% MnO2/SnO2, reaction temperature of 75 °C, and reaction time of 100 min, extraction: acetonitrile, agitation speed of 900 rpm, and mixing time of 30 min) via the catalytic oxidative-extractive desulfurization process was 92.4 and 91.2%, respectively. Also, the MnO2/SnO2 catalyst activity was studied after six consecutive oxidation cycles at the best operating conditions, and the catalyst prove satisfactory stability in terms of sulfur compounds removal. After that, the spent catalyst were regenerated by utilizing different solvents (methanol, ethanol and iso-octane), and the experimental data explained that iso-octane achieved highest regeneration efficiency.

Methyl Decanoate (MeDC) is a Fatty Acid Methyl Ester (FAME) and is an important chemical compound with global production of 31 million tons per year. However, synthesis of methyl decanoate (MeDC) via esterification of Decanoic Acid (DeC) with methanol by reactive distillation is operationally challenging due to difficulty of keeping the reactants together in the reaction zone as methanol being the lightest component in the mixture can separate itself easily form the other reactant deteriorating significantly the conversion of DeC using either conventional batch or continuous distillation column. This is probably the main reason for not applying the conventional route for MeDC synthesis. Whether Semi-batch Distillation column (SBD) and the recently developed Integrated Conventional Batch Distillation column (i-CBD) offer the possibility of revisiting such chemical reactions for the synthesis of MeDC is the focus of this paper. The minimum energy consumption (Q tot) as the performance measure is used to evaluate the performances of each of these reactive column configurations for different range of methyl decanoate purity and the amount of product. It is observed that the use of i-CBD column provides much better performance than SBD column in terms of the production time and the maximum energy savings when excess methanol is used in the feed. However, the SBD column is found to perform better than the i-CBD column when both reactants in the feed are in equal amount. Also, the optimization results for a given separation task show that the performance of two-reflux intervals strategy is superior to the single-reflux interval in terms of operating batch time, and energy usage rate in the SBD process at equimolar ratio.

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