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1 bar), which is expected to reach a glycerol conversion of 80%. The condensate stream with the products, unconverted reactants and catalyst follows to a filter to remove the catalyst. The filter’s outlet stream is inserted in the first distillation column to separate the remainder of acetone and water, which is the most energetically demanding step. The bottom stream follows to the second distillation column to obtain high purity solketal Sustain. Chem. 2021, 2 312 (99.6%) and the unreacted glycerol that will be recycled back to the system. Acetone is not recycled [122]. Figure 11. Flowsheet of the industrial solketal production plant proposed by da Silva et al. [122]. Figure 11. Flowsheet of the industrial solketal production plant proposed by da Silva et al. [122]. One of the most significant economic concerns of an industrial plant is the catalyst cost. One of the most significant economic concerns of an industrial plant is the catalyst SnF2 is highly recoverable and recyclable; therefore, it was assumed to be replaced twice cost. SnF2 is highly recoverable and recyclable; therefore, it was assumed to be replaced a year, accounting for only 0.005% of the annual operating costs. The other consumables account for nearly 17.50% of the operating costs. The total cost of producing solketal was US$1229/ton; thus, when compared to the selling price stated by Al-Saadi et al. of US$3000/ton, one can assume implementing a solketal production plant would be highly profitable [122,123]. Al-Saadi et al. simulated and compared the performance of three industrial flowsheets: (I) a one-stage solketal process plant operated at 8.5 wt% Sulphonic Acid-Functionalized Copolymer catalyst (ST-DVB-SO3H), 323 K, and a glycerol to acetone molar ratio equal 1:6, obtaining 87% solketal yield; (II) a similar plant with a glycerol to acetone molar ratio equal to 1:12, obtaining 98% solketal yield; (III) and a two-stage plant with the first step operating at 8.5 wt% ST-DVB-SO3H, 323 K, and a glycerol to acetone molar ratio equal to 1:10, obtaining 84% solketal yield in the first step, followed by removal of formed water, and another reaction under the same conditions to achieve 98% solketal yield. The two-stage plant (Figure 12) was found to be the most economically appealing, because the separation costs were lower than the one-stage processes, resulting, according to the authors, in a Net Present Value (NPV) 45.7% higher when compared with (I) and 0.57% higher when compared with (II); therefore, (III) will be described further [25]. The flowsheet comprises two mixers, the first to unite recycled and fresh acetone, followed by the second where glycerol is inserted. Then, the stream is heated in a heat exchanger up to the reaction temperature, which occurs in a plug-flow reactor packed with the catalyst. The first reaction’s product stream is separated in a distillation column, the acetone recovered as distillate is reinserted in the second reactor and the bottom stream containing glycerol, water, and solketal is fed to a separation unit (not specified), where water is removed. The products stream is cooled in a heat exchanger prior to being fed to the second reactor, where almost all the remainder glycerol is converted. What follows is the second distillation column, where acetone is collected and recycled back to the system and solketal is the bottom product with a content of 98% solketal and 2% glycerol. According to the authors, the separation cost is lower because, in the second reaction, only 0.16% of the products’ stream is water. The cost of producing solketal in the described plant, considering a capacity of 100,000 t/years and a 20-year lifetime, was estimated at $2058/ton, well below the selling value reported by the authors US$3000/ton [25].PDF Image | Continuous Valorization of Glycerol into Solketal
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