Pilot scale (10Â kg) production and characterization of epoxidized sucrose soyate

- A 38 L jacketed kettle was successfully adapted as a reactor to synthesize 10 kg of epoxidized sucrose soyate within 5.5 h timeframe similar to the 300 g laboratory scale.
- Refining units were designed and fabricated to safely and efficiently purify the synthesized resin which helped reduce the total production time from 8 to 4 days.
- Twenty 7-10 kg batches were produced which had similar resin quality as the lab scale with an overall 87.5% resin yield and >98% conversion of double bonds after batch three.

The objective of this study was to develop and characterize the performance of a reactor and refining units that would produce 10 kg of epoxidized sucrose soyate (ESS) with a process timeframe and resin quality similar to the 300 g laboratory scale in order to meet the increasing demand for multiple applications in coatings and composite materials. Scale up challenges involve maintaining suitable reaction temperature and time, achieving high double-bond conversion, minimizing side reactions, and avoiding excessive refining time. To accomplish this, a 38 L stainless steel steam-jacketed GROEN kettle was modified for use as an epoxidation reactor. The modifications helped achieve adequate mixing, heat transfer and temperature control. Consequently, the reaction temperature was successfully controlled between 55 and 65 °C by varying the H2O2 addition rate and the fluid temperature in the reactor's jacket. Twenty 7-10 kg batches were produced which had similar resin quality as the lab scale, an overall 84.9% resin yield, and >98% conversion of double bonds after batch three. The total production days were reduced from 8 to 4 after a 40 L refining funnel was fabricated for washing, gravity phase separation, and filtration, and an explosion-proof solvent extraction unit was adapted for devolatilizing hexane used during refining. The overall heat transfer coefficient of the jacket was determined to be 1069 W m−2 K−1.