Continuous‐flow synthesis of the selective herbicide pendimethalin was demonstrated in both a laboratory‐scale and a pilot‐scale reactor using only concentrated nitric acid as nitrating agent. The di‐nitration reaction follows second‐order kinetics where the reaction is first order with respect to both reactant and nitric acid. The pinched‐tube reactor was chosen for pilot‐scale reactor fabrication due to its excellent mixing and mass transfer characteristics compared to a straight‐tube reactor. The estimated mass transfer coefficient showed similar nature in the laboratory‐scale and the pilot‐scale pinched‐tube reactor, ensuring similar performance at the pilot scale. Di‐nitration in continuous flow, inline quenching, extraction, and phase separation are some of the salient features of the developed pilot plant. The importance of the start‐up time for achieving steady state in the flow system at the large scale is highlighted.

Scale-up of the di-nitration reaction for synthesis of selective herbicide pendimethalin using only nitric acid in continuous flow is presented in this work. This work showcases an approach for smooth scale-up for an herbicide for a production capacity of 50 kg/ day using a pinched tube reactor. The approach begins with the batch experiments followed by flow synthesis using a 1/8-inchSS316 helical coil tube where kinetics of the di-nitration was determined, and process optimization was done. Systematic approach was followed for quantification of heat transfer, mass transfer and residence time distribution and scale-up. Detailed scale-up methodology is presented with effect of relevant parameters for successful scale-up. Modular pilot plant with inline quenching, extraction and separation are some of the salient features presented in this work.