(219b) The Mesoscale Oscillatory Baffled Reactor as a Robust Intensification Reactor for Rapid Process Development

Multi-dimensional, dynamic and continuous steady state screening of an acid-catalysed esterification reaction were carried out using a mesoscale oscillatory baffled reactor (“meso-OBR”) to investigate the ability of the reactor for solid-liquid reactions. Sulphonic acid functionalised Amberlyst (Amberlyst^TM 70) was used as a catalyst for the reaction at a temperature of 60 °C under an oscillation condition (frequency of 4.5Hz and amplitude of 8mm) at methanol to hexanoic acid molar ratios of 1:1 – 30:1 and residence times ranging from 1min to 20min.. Steady states were achieved at all the residence times used for the continuous multi-steady states and all the ramped feed molar ratios. The hexanoic acid conversions increased with residence time from 54.98 ± 0.86% at 2.5min through 80.05 ± 1.39% at 10min to 95.43 ± 1.04% at 20min residence times and 30:1 methanol to hexanoic acid molar ratio. The Amberlyst^TM 70 recovered its catalytic activity fully after the system was spiked with water, indicating that the catalyst does not suffer permanent deactivation in the presence of water. The hexanoic acid conversions were similar and reproducible for the multi-dimensional, dynamic and continuous steady states. These results showed that rapid process development can be achieved using the meso-OBR in multi-dimensional and dynamic modes.