Bridging the Gap from Laboratory to Production: Kinetic Modeling-Guided Process Development for a Novel Epoxy Resin

The development of a production process of the sustainable epoxy resin 1,2-epoxy-6-methyl-triglycidyl-3,4,5-cyclohexanetricarboxylate (EGCHC) is presented. The three main sections of the suggested process flowsheet follow the reaction steps beginning with allyl sorbate and maleic anhydride. The Diels-Alder, allylation, and epoxidation reactions are simulated in Aspen Plus V12 and connected to form a single process train. To size and establish key process parameters, simulations supported by kinetic data for each reaction are performed. The [4 + 2]-cycloaddition and epoxidation are implemented in multitubular plug flow reactors with downstream crystallizers for product purification. The allylation reaction is carried out in a reactive distillation column to separate the heavy boiling product from the condensate/allyl alcohol mixture, which is further processed to regain allyl alcohol. To decrease the intake of raw materials, recycle streams are added to each sections. EGCHC is achieved with a purity of 95%, which can be employed with standard curing agents to form dense cross-links due to an average number of epoxy groups >3.96 in the product stream. Furthermore, a techno-economic analysis is performed, showcasing a competitive market price for EGCHC with the given process design in the segment of biobased epoxy resins. This study demonstrates a comprehensive strategy that allows for rapid implementation of a novel synthesis process based on preliminary laboratory measurements and rating thereof.