Process Intensification via Integration of Reaction and separation in a Horizontal Thin Film Evaporator

Process intensification can be achieved in specialty chemicals manufacturing via transition from batch-to-continuous processing. However, the absence of headspace in a continuous tubular reactor limits the ability to remove volatile byproducts from the reacting liquid flow. Previous studies showed that the production of succinimide dispersants follows a two-step amidation-dehydration pathway in which water is formed as a by-product. The inability to remove this water imposed a thermodynamic equilibrium limitation on the dehydration step, and hence necessitated a downstream drying step to obtain a dehydrated dispersant product within commercial specifications. In the present study, the use of an agitated, horizontal thin film evaporator (TFE) was investigated as a continuously operated reactive separator which combines reaction and dehydration into a single operating unit, reducing the overall cost and physical footprint of the process. The continuous TFE unit was first experimentally investigated as a stand-alone, integrated reactor-separator. Using this configuration, the obtained imide yield consistently exceeded the maximum thermodynamic yield at each operating temperature, confirming the efficiency of the integrated reaction and separation steps in the TFE. Next, the unit was modeled by integrating reaction kinetics with mass and energy balance equations, using appropriate correlations for heat and mass transfer from the literature which were verified for the experimental set-up. This model provided insights into the system behavior across different operating conditions, including the role of forward and reverse reactions along the TFE unit length. The model was then used to confirm the feasibility of replacing the two-step tubular reactor-evaporator process with a single TFE unit as an intensified reactive separator, further reducing the physical footprint of the process by enabling compact modular process designs.