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Comparison of Different Synthesis Schemes for Production of Sodium Methoxide from Methanol and Sodium Hydroxide

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Comparison of Different Synthesis Schemes for Production of Sodium Methoxide from Methanol and Sodium Hydroxide Article Comparison of Different Synthesis Schemes for Production of Sodium Methoxide from Methanol and Sodium Hydroxide Natthiyar Aeamsuksai1,a, Thirawat Mueansichai2,b,*, Pongtorn Charoensuppanimit3,4,c, Pattaraporn Kim-Lohsoontorn1,4,d, Farid Aiouache5,e, and Suttichai Assabumrungrat1,4,f 1 Center of Excellence in Catalysis and Catalytic Reaction Engineering, Department of Chemical Engineering, Faculty of Engineering, Chulalongkorn University, Bangkok 10330, Thailand 2 Department of Chemical and Materials Engineering, Faculty of Engineering, Rajamangala University of Technology Thanyaburi, Pathumtani 12110, Thailand 3 Control and Systems Engineering Research Laboratory, Department of Chemical Engineering, Faculty of Engineering, Chulalongkorn University, Bangkok 10330, Thailand 4 Bio-Circular-Green-economy Technology & Engineering Center, BCGeTEC, Department of Chemical Engineering, Faculty of Engineering, Chulalongkorn University, Bangkok 10330, Thailand 5 Department of Engineering, Lancaster University, Lancaster LA1 4YW, United Kingdom E-mail: [email protected], [email protected] (Corresponding author), [email protected], [email protected], [email protected], [email protected] Abstract. This research investigates the process simulation of sodium methoxide (NaOCH3) synthesis from methanol (CH3OH) and sodium hydroxide (NaOH) under three synthesis schemes: schemes A, B, and C. Scheme A consisted of one equilibrium reactor and two distillation columns, scheme B one reactive distillation column and one distillation column, and scheme C one reactive distillation column and pervaporation membrane. The simulation parameters included CH3OH/NaOH feed flow ratio (1.2-1.6), number of stages (5-30), bottom flow rate (1400-1600 kg/h), and feed stage location (5, 10, 15, 20, 21, 22, 23, and 24). The simulation parameters were varied to determine the optimal NaOCH3 synthetic conditions under different schemes with 0.01 wt% water content, maximum 45 wt% NaOCH3, and the lowest total energy consumption. The results showed that scheme C had the lowest total energy consumption (34.25 GJ/h) under the optimal synthetic condition of 1.4 for CH3OH/NaOH feed flow ratio, 25 for the number of stages, 1550 kg/h for the bottom flow rate, and the 24th feed stage location, with the NaOCH3 flow rate of 675 kg/h. Scheme C thus holds promising potential as an energy-efficient alternative for synthesis of NaOCH3. The novelty of this research lies in the use of pervaporation membrane in place of distillation column to separate CH3OH from water and to lower energy consumption and capital cost. Keywords: Sodium methoxide, methanol, sodium hydroxide, reactive distillation, pervaporation, process simulation. ENGINEERING JOURNAL Volume 24 Issue 6 Received 20 July 2020 Accepted 7 November 2020 Published 30 November 2020 Online at https://engj.org/ DOI:10.4186/ej.2020.24.6.63 DOI:10.4186/ej.2020.24.6.63 1. Introduction neither additional reactor nor second distillation column, resulting in lower capital cost. The proposed distillation- Sodium methoxide (NaOCH3) is a high-performance pervaporation technology also reduces the amounts of alkoxide catalyst that is primarily used in the biodiesel unreacted CH3OH and multiple recycling, thereby production from waste cooking oil [1], waste chicken fat lowering energy consumption. [2], palm oil [3], canola oil [4], as an intermediary in 1G- Specifically, this research investigates the process biodiesel [5], and enzymatic saccharification enhancer [6]. simulation of NaOCH3 synthesis from CH3OH and In biodiesel production, 25-30 wt% NaOCH3 in NaOH under three synthesis schemes: schemes A, B, methanol (CH3OH) is used as homogeneous catalyst for and C. Scheme A consisted of one equilibrium reactor transesterification reaction [7]. NaOCH3 is a more and two distillation columns, scheme B one reactive effective alternative to alkaline metal hydroxides to distillation column and one distillation column, and improve the yield and purity of biodiesel [1]. Existing scheme C one reactive distillation column and NaOCH3 synthesis technologies include the reactor- pervaporation membrane. The simulation parameters distillation-distillation system [8, 9] and reactive included CH3OH/NaOH feed flow ratio (1.2, 1.3, 1.4, distillation-distillation scheme [10-12]. Sodium hydroxide 1.5, 1.6), number of stages (5, 10, 15, 20, 25, 30), bottom (NaOH) is commonly used as the precursor for flow rate (1400, 1450, 1500, 1550, 1600 kg/h), and feed industrial-scale production of NaOCH3 due to low cost stage location (5, 10, 15, 20, 21, 22, 23, and 24). The and low toxicity. simulation parameters were varied to determine the In [13], reactive distillation was used to enhance optimal NaOCH3 synthetic conditions under schemes A, dimethyl carbonate synthesis. The reactive distillation B, and C, with 0.01 wt% water content, maximum 45 wt% was also used to convert vegetable oil into biodiesel [14, NaOCH3, and lowest total energy consumption. 15]. In [7], different NaOCH3 synthetic strategies, including reactive distillation, were investigated and 2. Modeling and Simulation results compared [7]. The final stage of NaOCH3 synthesis involves Simulations were carried out by using ASPEN Plus separating CH3OH from water. The distillation to determine the optimal NaOCH3 synthetic conditions technology is commonly utilized to separate between that minimize the energy consumption of schemes A, B, water and the raw material (CH3OH) which is recycled to and C, given 0.01 wt% water content and maximum 45 the synthetic system. The construction of a distillation wt% NaOCH3. column requires substantial financial investments. As a result, pervaporation technology was proposed to 2.1. Reaction Model separate the material from water [16-20]. In [16], pervaporation was used to esterify organic NaOCH3 is synthesized by reversible exothermic acids and improve the conversion of the reactants. In reaction which is expressed in Eq. (1). [17], the reactive distillation augmented with pervaporation was used to synthesize ethyl tert-butyl CH3OH + NaOH ↔ NaOCH3 + H2O (1) ether (ETBE) from ethanol and tert-butyl alcohol. The pervaporation efficiently removed water from the It is assumed that a hydroxide-methoxide ionic bottom product, enhancing the fraction of ETBE in the equilibrium (Eq. (2)) is achieved once CH3OH and top product. In [18], the reactive distillation integrated NaOH species are mixed [19]. with zeolite NaA membrane-based pervaporation was utilized to etherify tert-amyl alcohol into tert-amyl ethyl CH3OH + OH- ↔ CH3O- + H2O (2) ether. The integrated scheme increased the tert-amyl ethyl ether yield by 10 %. The pervaporation was also In terms of ion activities (a), the equilibrium constant used to separate bioethanol [19] and biodiesel-CH3OH of the hydroxide-methoxide ionic equilibrium (K) is mixture [20]. expressed in Eq. (3). The reactor-distillation-distillation and reactive a(x) a(x) OCH H2O distillation-distillation technologies are commonly used in K = 3 (3) a(x) a(x) biodiesel production. However, the reactor-distillation- CH3OH OH distillation technology suffers from limited equilibrium The temperature-dependent equilibrium constant (K) is conversion which results in low single-pass conversion expressed in Eq. (4). Equation (4) was derived from the and high energy consumption (i.e., operating cost) due to linear regression of the experimental data in [7, 21]. high amounts of unreacted raw material (CH3OH), requiring multiple recycles. Meanwhile, the reactive ln K = -4.374 + 1751/T (4) distillation-distillation scheme predominantly suffers from high energy consumption due to high amounts of where K is the chemical equilibrium constant and T is unreacted CH3OH. the system temperature in Kelvin. In Eq. (4), the As a result, this research proposes a novel reactive equilibrium constant (K) decreases with increase in the distillation-pervaporation technology which requires 64 ENGINEERING JOURNAL Volume 24 Issue 6, ISSN 0125-8281 (https://engj.org/) DOI:10.4186/ej.2020.24.6.63 system temperature due to the exothermicity of the The separation factor (α) of the membrane is reaction. calculated by Eq. (7), where y and x are permeate and feed composition [24]. 2.2. Process Modeling ya yb αab = (7) x x The vapor-liquid equilibrium calculations under a b schemes A, B, and C were performed using the electrolyte non-random two-liquid with Redlich-Kwong Table 1. Simulated NaOCH3 synthesis schemes. equation of state (eNRTL-RK) model. The eNRTL-RK model is ideal for an electrolyte system for ionic species Scheme A Scheme B Scheme C in asymmetric reference state [7, 22]. The eNRTL model Prediction ENRTL- ENRTL- ENRTL-RK + can describe the interaction between electrolyte models RK RK MESH molecules in liquid phase, and the RK model is used to Number of 3 units 2 units 2 units characterize the non-ideal behavior of vaporized operating units molecules in gas phase. The interactions between water Reaction REQUIL RadFracb RadFracb and CH3OH; and between water and NaOCH3 were reactor a b b from the ASPEN Plus database, while the interaction NaOCH3 RadFrac RadFrac RadFrac between NaOCH3 and CH3OH was from [7]. separator a a The MESH (material balance, vapor-liquid CH3OH RadFrac RadFrac Pervaporation equilibrium equations, mole fraction summations, and separator membrane heat balance) model was used to characterize the reactive Note: a denotes the ordinary distillation column, and b denotes the distillation-pervaporation process (scheme
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