Dynamic Modeling and Robust Optimal Operation of the Hydrothermal Synthesis of Zeolites in a Continuous Oscillatory Baffled Reactor

Continuous flow synthesis offers major advantages in the production of specialty products, e.g. zeolites, such as tight temperature control and lower variation in product quality. Here we consider the hydrothermal synthesis of NaX zeolites in a continuous oscillatory baffled reactor (COBR). A process model is derived from physico-chemical relationships to analyze and optimize the operation of a pilot scale continuous oscillatory baffled reactor for zeolite synthesis. The process model is validated using plant data. Furthermore, the uncertainty of the model predictions is quantified. Based on this analysis, robust optimization is used to compute robust optimal operation points of the COBR. These optimal operation points are validated by the application to a real pilot plant.