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Dimethyl carbonate is a green compound with a broad variety of application. In the study, the process design and control of synthesizing propylene carbonate (PC) for the dimethyl carbonate production by using CO2 as a raw material is investigated by indirect alcoholysis of urea. This attractive indirect alcoholysis route of urea shows many advantages such as environmentally friendly chemicals, cheap raw materials, and mild and safe operation condition. Some reaction distillation (RD)-based processes for PC synthesis by this route are proposed, designed, and optimized in this work. These processes consist of two operation configurations, near neat operation and excess reactant operation. The intensified technologies of heat integration in addition to RD are used to design economic PC synthesis processes. Steady-state simulation results indicate that the novel intensified process containing a RD column and a conventional distillation column with internal vapor compression provides the most economical design. This process is operated under excess reactant and fully utilizes the special azeotrope characteristic of propylene carbonate and propylene glycol pair. This pair forms a homogeneous minimum-boiling azeotrope near the pure PG end under low pressure. However, this azeotrope vanishes under high pressure. Furthermore, steady-state analysis is used to design a simple temperature control strategy. Different desired temperature profiles can be found in the RD column under various feed flow rates. Set point of the temperature loop for maintaining bottom product purity of the RD column is then reset when throughput rate changes. Dynamic simulation results reveal that the proposed temperature control can maintain product purities at their desired values in face of feed flow disturbances.

Design and Control of a Reactive Distillation Process for Synthesizing Propylene Carbonate from Indirect Alcoholysis of Urea