A novel approach for the design and synthesis of membrane separation systems has been developed. The theory is shown to be applicable to both batch and continuous membrane operations, and has been formulated in such a way that it is valid for any type of membrane. In this thesis, however, only vapour permeation and pervaporation membranes are incorporated for illustration purposes. The method, which employs a graphical technique, allows one to calculate and visualise the change in composition of the retentate. An integral part of the approach was the derivation of the Membrane Residue Curve Map (M-RCM), and the related differential material balance which describes it. By definition, this plot shows the change, in time, of the retentate composition in a batch still. However, it has been shown that the M-RCM is applicable to conventional continuously-operated membrane units, as well as infinite reflux membrane columns. Finite reflux columns and cascades have been examined by using column sections (CS): any column, or arrangement, no matter how complex, can be broken down into smaller units, namely CS. The development of the Difference Point Equation (DPE) for non-constant flow allowed one to generate, and interpret, profiles for individual CS’s, which can ultimately be connected to form a membrane column arrangement. The profiles, which are more complex than those obtained in the M-RCM, exhibit a unique behavior. Since there is varying flow, the reflux is continually changing, orientating the profile so as to seek a stable node that is “mobile”. Thus, the movement of CS profile is dictated by the location and direction of the pinch point locus. Finally, having membrane permeators examined in an analogous manner to other separation methods, allows for easy synthesis and design of combinations of different processes. Hybrid distillation-membrane systems are analyzed by incorporating CS’s and the appropriate DPE’s which describe each. Investigating the arrangement as a thermally-coupled column introduces a novel way of synthesizing hybrids. Regions of feasibility, which are dictated by the relevant pinch point loci of each separation method, are ultimately sought.

With ever-growing environmental concerns, petrochemical and fine chemical industries face an omnipresent issue in recovering acetic acid from its aqueous solutions. The recovery of acetic acid through the esterification process is a very viable option. However, esterification reactions are typically restricted by equilibrium limitations, and face challenges with product purification. Reactive distillation is an emerging technology that has an extremely attractive potential as a process alternative for carrying out equilibrium limited chemical reactions. Although the reactive distillation process has been successfully commercialised for the manufacture of hIgh commodity chemicals e.g. methyl tertiary butyl ether (MTBE) and methyl acetate, its potential as a separation tool for the recovery of acetic acid using iso-amyl alcohol has not been exploited.

Petrochemical and fine chemical industries face a daunting problem in recovering acetic acid from its aqueous solutions. The recovery of acetic acid could be done through esterification reaction. However, esterification is an equilibrium limited reaction. Multi-functional reactors such as chromatographic reactor (CR) and reactive distillation column (RDC) are promising technologies mainly for equilibrium limited reactions wherein reaction and separation of products are carried out in a single equipment that tends to shift the equilibrium towards the desired direction which is not possible in a classical batch reactor. Physical and chemical characterisation of ion exchange resin catalysts such as scanning electron microscopy, Brunauer-Emmett-Teller (BET) surface area measurement, pore size distribution, elemental analysis, true density and particle size distribution were carried out to access the catalysts performance for n-hexyl acetate synthesis. Esterification of acetic acid with n-hexanol was studied with both dilute and concentrated acid in the presence of cation exchange resins (macroporous and gelular) in a jacketed stirred batch reactor to synthesise a value added ester, namely n-hexyl acetate and also to study the recovery of acetic acid from the waste aqueous streams. The effect of various parameters such as speed of agitation, catalyst particle size, feed mole ratio of n-hexanol to acetic acid, reaction temperature, catalyst loading and reusability of catalysts was studied for the optimisation of the reaction condition in a batch reactor. The non-ideality of each component in the reacting mixture was accounted for by using the activity coefficient via the use of the UNIFAC group contribution method. The kinetic data were correlated with both pseudo-homogeneous (PH) and adsorption based heterogeneous reaction rate models, e.g., Eley-Rideal (ER), Langmuir-Hinshelwood-Hougen-Watson (LHHW), and the modified LHHW (ML). Pseudo-homogeneous (PH) model gave the best representation of the kinetic data found experimentally. The feasibility of reactive distillation for the recovery of acetic acid using n-hexanol was evaluated through residue curve map (RCM) determination experiments. RCM provides information to a design engineer of the existence of separation boundaries imposed by the singular points corresponding to the reactive/non-reactive azeotropes, thus provides an insight into the feasibility of reactive distillation for this purpose. A laboratory scale batch chromatographic reactor was designed and constructed. Batch chromatographic reactor experiments were carried out using different parameters such as feed flow rate, feed mole ratio of n-hexanol to acetic acid, desorbent (n-hexanol) flow rate and reaction step to maximise the formation of n-hexyl acetate as well to achieve complete conversion of acetic acid. Continuous chromatographic reactor was designed, constructed and commissioned on the basis of the results obtained from the batch chromatographic reactor experiments. The experiments carried out in continuous chromatographic reactor correlated very well with the results from the batch chromatographic reactor for the optimised condition.