2-Ethylhexyl acrylate is commercially produced from acrylic acid and 2-ethylhexanol using sulfuric acid as catalyst. Employing solid catalysts can eliminate corrosion, increase selectivity, and make easier the separation and product purification. Process development studies for a complete plant have not been reported in the literature. In this paper, the design, control, and economic evaluation of three reaction–separation–recycle processes are developed. The reaction takes place in a fixed-bed reactor using Amberlyst 70 as catalyst. The acrylate is recovered by distillation at the desired purity. One of the processes obtains high-purity wastewater by removing the water in a distillation–decanter system. The other two obtain low-purity water in a flash-decanter, and a decanter-only system, respectively. All three processes are controllable, the control system showing robustness when an increase or decrease in production capacity is required, or when the fresh reactants become contaminated. The economic analysis shows attractive economic potential and other key economic indicators.

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Methyl methacrylate is an essential chemical used as raw material for the production of other methacrylates and poly-methyl methacrylate. There are various chemistry routes, available or not on the industrial scale, to produce methyl methacrylate. These routes use the same or different raw materials and present common chemistry and processing steps. Many of these routes though, have as a final step the esterification of methacrylic acid with methanol to obtain methyl methacrylate. However, there is no complete process described in the literature for this final esterification step. This paper is the first to propose a solid-based catalytic process for methyl methacrylate production starting from methyl methacrylate and methanol, in a continuous reaction–separation–recycle system. In this specific case, this system is more suitable than reactive distillation due to the unfavorable ranking of boiling points and also due to the presence of several potentially hindering azeotropes. This work also provides an original framework for simulation of other methyl methacrylate processes, by deriving detailed equilibrium and kinetic parameters based on literature experimental data. Rigorous process simulations are carried out in Aspen Plus and Aspen Plus Dynamics for the design and control of the new process. The flowsheet consists mainly of a fixed-bed tubular reactor followed by a sequence of three distillation columns coupled with a decanter. The results show that the process is technically feasible, cost-effective in terms of total annualized costs, and with excellent sustainability metrics, requiring only 2.05 MJ/kg of methyl methacrylate produced.