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.