Abstract
Despite the overarching necessity for sustainability, the realization of novel process concepts using innovative green reaction media, such as microemulsions is still hindered by their inherent complexity. To overcome this, a holistic guideline for the fast-track realization of microemulsion systems is presented and applied on a mini-plant for the hydroformylation of 1-dodecene in microemulsions. It combines a rigorous system analysis and identification of challenges for process design and operation. Here, critical unmeasurability of concentrations, small feasible operation regions, and a highly dynamic system behavior are identified. This is encountered by tailored PSE methods: a dynamic model for the complex three-phasic separation of microemulsions, the formulation of a concentration soft-sensor, as well as multi-rate moving horizon state estimation and subsequent dynamic real-time optimization. Applying those, stable operation of the mini-plant for up to 200 h is ensured together with a steady-state product yield of 38% and a product selectivity of 92%.
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