Patel, Riddhesh Ashokbhai
(2024)
Batch-to-Continuous Transition in Specialty Chemicals Industry: Intensified Dispersants
Production.
Doctoral Dissertation, University of Pittsburgh.
(Unpublished)
Abstract
The specialty chemicals industry relies heavily on batch reactor technology due to its
operational simplicity and versatility in handling diverse chemistries. However, batch reactors face
significant challenges in large-volume production, including heat and mass transfer limitations
which result in poor operational efficiency, and safety concerns when processing large volumes of
hazardous chemicals. Transitioning to modular continuous processing units holds the potential for
addressing these challenges, as demonstrated in our previous study of succinimide dispersants
production.
The first part of the dissertation aims at back-integrating succinimide dispersant production
by transitioning the production of a key reactant, polyisobutenyl succinic anhydride (PIBSA), from
batch to continuous operation and thus unlocking the full benefits of continuous operation for the
overall process. PIBSA is produced via reaction of polyisobutylene (PIB) with maleic acid
anhydride (MAA) and poses significant challenges for continuous processing, including slow
intrinsic kinetics and hence long batch times at typical operating conditions, poor miscibility
between reactants that result in strong mass transport limitations, and solid byproducts formation
due to the high reactivity and thermal instability of MAA. We address these issues by (i)
demonstrating novel ways for mitigating MAA side reactions via enhanced reactor mixing, and
(b) acquiring the first robust reaction kinetics for PIBSA formation, which are then used to model
different reactor operation schemes to identify suitable operating conditions for continuous
processing. Overall, this work supports the transition from batch to continuous processing for
v
PIBSA production via a recycle reactor operation, aimed at integrating succinimide dispersant
production into a fully continuous process, thereby improving operational efficiency and
scalability.
The second part of this dissertation briefly evaluates a hydrodynamic cavitation reactor as
a novel reactor concept for succinimide dispersants production by investigating its heating, mixing,
and reactive performance. Counter to expectations, however, our findings indicate that cavitation
phenomena offer little to no additional intensification potential over conventional tubular reactor
operations.
In summary, this dissertation elucidates the methodology for transitioning from batch to
continuous processing in the specialty chemicals sector.
Share
| Citation/Export: |
|
| Social Networking: |
|
Details
| Item Type: |
University of Pittsburgh ETD
|
| Status: |
Unpublished |
| Creators/Authors: |
|
| ETD Committee: |
|
| Date: |
6 September 2024 |
| Date Type: |
Publication |
| Defense Date: |
8 July 2024 |
| Approval Date: |
6 September 2024 |
| Submission Date: |
24 July 2024 |
| Access Restriction: |
2 year -- Restrict access to University of Pittsburgh for a period of 2 years. |
| Number of Pages: |
203 |
| Institution: |
University of Pittsburgh |
| Schools and Programs: |
Swanson School of Engineering > Chemical Engineering |
| Degree: |
PhD - Doctor of Philosophy |
| Thesis Type: |
Doctoral Dissertation |
| Refereed: |
Yes |
| Uncontrolled Keywords: |
Process Intensification, Batch-to-continuous, Specialty chemicals |
| Date Deposited: |
06 Sep 2024 20:05 |
| Last Modified: |
06 Sep 2024 20:05 |
| URI: |
http://d-scholarship.pitt.edu/id/eprint/46746 |
Metrics
Monthly Views for the past 3 years
Plum Analytics
Actions (login required)
 |
View Item |
![[img]](https://d-scholarship.pitt.edu/style/images/fileicons/application_pdf.png)
![[feed]](/images/feed-icon-32x32.png){kind=icon}