Optimisation of industrial-scale n-butyl acrylate production using reactive distillation

The current production process for the synthesis of n-butyl acrylate is challenging and cost intensive, due to a complex thermodynamic behaviour and a high risk of polymerisation. An integration of chemical reaction and distillation into one unit at the same time can be done by reactive distillation (RD). RD is one of the best known examples of process intensification. In order to facilitate the industrial application of this concept for the production of n-butyl acrylate, a process optimisation is presented in this article. A nonequilibrium-stage model is used, which was validated using experimental data in an earlier study. The packing characteristics are adapted to an industrial scale column to allow a reliable optimisation. The validated model is used to perform a process optimisation of two process configurations which are a single RD column and an RD column coupled with a decanter at the top to allow a recycling of unused reactants. Finally, an economic evaluation of both introduced processes and a comparison to the conventional process will be shown which identifies the coupling of reactive distillation with a decanter as the most economic process for the production of n-butyl acrylate. (C) 2013 Elsevier Ltd. All rights reserved.