Reactive separation is an intensified method for the separation of carboxylic acids from dilute aqueous solutions. In this respect, separation of acrylic acid was studied employing reactive separation using various combinations of extractants (TBP, TOA and Aliquat336) and diluents (octanol and toluene). The results were compared with the previous published works and it was observed that TOA + octanol system is the most efficient combination (extraction efficiency (η)> 95 %). Synergism was observed when the extractants were used in mixed form (Aliquat336-TOA, TBP-TOA and Aliquat336-TBP), providing equivalent separation to TOA alone and is proposed to be a cost-effective solution for reactive separation of acrylic acid. Also mixed diluents (octanol + toluene) were tried with individual extractants to combat the emulsion problem when toluene was used alone. Mathematical modelling (using the law of mass action) was carried out and loading curves were validated by mathematical models. Binary extractant/diluents combination could be proposed as cheap and effective solution to the high prices of solvents used for acrylic acid recovery. Regeneration of acid from loaded organic phase was carried out by temperature swing (recovery of 69 %) and contact with NaOH (recovery >95 %). Design parameters for the RDC extraction column were also obtained.
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