Continuous-flow synthesis of di-(2-ethylhexyl) peroxydicarbonate in a packed-bed microreactor: Process optimization and kinetic modeling

Di-(2-ethylhexyl) peroxydicarbonate (EHP) is a low-temperature liquid organic peroxide commonly used as an initiator for polymerization of vinyl chloride and ethylene. The exothermic nature of peroxidation and the instability of this peroxide product pose safety challenges during synthesis. Therefore, batch reaction processes for synthesizing such products often prioritize safety over efficiency. In this work, an efficient and safe protocol was proposed for EHP production with the use of a packed-bed microreactor. Response surface methodology was applied to optimize critical process parameters, resulting in a remarkable yield of 95.48% in a residence time of 23.8 min. It proves that the efficiency was significantly improved by the packed-bed microreactor compared with batch reactors. Additionally, an operational window was established to guide the process development for synthesizing EHP in flow. Finally, a kinetic model was established, which was of crucial theoretical significance and practical value for better understanding peroxidation processes and parameter optimization.