Direct esterification in helical continuous-flow microreactors under an aqueous environment: optimization, reaction kinetics, and process intensification

This study presents an optimized process for producing long-chain alkyl acrylates via direct esterification in a helical continuous-flow microreactor. Addressing the inefficiencies of traditional batch esterification, such as low energy efficiency and slow mass transfer, this method utilizes continuous-flow chemistry for more effective, ecofriendly, and cost-efficient production. The microreactor, with a 10 m long and 0.5 mm diameter helical microchannel, which active volume was 3.925 ml, was examined for its performance influenced by reactantcatalyst ratios, temperature, and residence time. Results show significantly improved yields of myristyl acrylate (over 89 % in 300 s, respectively) while the residence time was 300 s at 110 +/- 10 degrees C, with a molar ratio of 1tetradecanol to acrylic acid of 1.3 and a catalyst to acrylic acid molar ratio of 0.1. Additionally, a second-order reaction kinetic model was developed to better understand the reaction dynamics in this setup. This research underscores the potential of integrating helical continuous flow with esterification, offering a novel approach to studying these mechanisms.