Transformation of the 2nd step of a peroxyester synthesis from semi-batch to continuous mode

• Peroxyester synthesis was carried out in continuous mode in safe manner.
• Without efficient mixing of educts reaction is limited by diffusion rate.
• Use of ultrasound enhances mixing of the two phase liquid/liquid system.
• Higher space time yield was achieved in comparison to semi-batch mode.

Organic peroxides are known for their decomposition behaviour and for considerable heat release connected with pressure build up. Efforts are required to run the industrial synthesis in semi-batch mode on safe condition. With the aim to use advantages as good heat transfer and small hold up, the synthesis of a peroxycarboxylic ester, namely tert-Butyl peroxy-2-ethylhexanoate (TBPEH), was transformed into continuous mode using a tube reactor with inner dimension of 1 mm. An appraisal of the critical diameter of the tube was done in advance. The use of an ultrasonic device allowed for specific reaction parameters a nearly complete conversion of the educts.