3.1. Effect of Mass Transfer
As indicated, the external and internal mass transfer limitations of resin catalysts in catalytic esterification reactions can be ruled out through varying stirring speed and particle sizes of catalysts [
3,
13,
14]. As presented in
Figure 1, it can be observed that varying stirring speeds within ranges of 200 to 600 rpm have no significant impact on the yield of PMA, indicating that the influence of external diffusion can be disregarded. Nevertheless, elevated rotational speeds may result in increased wear between the rotor and catalyst particles, which is detrimental to the recovery and reuse of the catalyst. Consequently, a stirring speed of 300 rpm can be established as the optimal setting for subsequent reaction process.
The particle diameter of the catalyst has a direct impact on internal diffusion. Previous studies have employed the method of varying catalyst particle diameter to investigate the effects of internal diffusion [
13,
14,
46,
47,
48]. The particle size of the cation exchange resin Amberlyst-35 is not homogeneous, making it difficult to study the effects of internal diffusion by particle size screening. In theory, the Weisz-Prater number (
Cwp) can be employed to assess the influence of internal diffusion on mass transfer in a reaction system catalyzed by a cation exchange resin [
49]. When
Cwp is much less than 1, the effect of internal diffusion on the mass transfer resistance of the reaction is negligible.
Cwp is calculated by
where -
robs represents the apparent rate of reaction,
Cs is the concentration of reactants on the catalyst surface,
De represents the effective diffusion coefficient,
ρc is the density of catalyst, and
Rc is the radius of catalyst particles (according to the manufacturer,
ρc is 0.75 g/cm
3 and
Rc is 0.035 cm).
De is calculated by
where
εc and
τ represent the porosity and tortuosity factor of catalyst particles (where
εc is assumed to be 0.35 and
τ is 1/
εc), respectively, and
DA is the infinite dilution diffusion coefficient.
DA can be calculated using the Wilke-Chang empirical correlation
where
Φ2 is the association factor of PM,
M2 is the molar mass of PM,
μ2 is the viscosity of PM, and
V1 is the molar volume of AA at normal boiling point.
Table 1 exhibits the calculated results of the Weisz-Prater parameter at different temperatures. Within the temperature ranges of 333.15 to 363.15 K, the
Cwp values are significantly smaller than 1, indicating that the influence of internal diffusion can be neglected.
3.2. The Effect of Reaction Conditions
The impacts of various reaction parameters, including catalyst loading, temperature and reactant molar ratio on the esterification of PM and AA were investigated. The effect of the amount of catalyst on the PMA yield was studied by varying catalyst loading from 5 to 12 wt% while all other reaction parameters kept identical. The results as illustrated in
Figure 2 demonstrate that when catalyst loading is below 10 wt%, an increase in the catalyst dosage leads to an acceleration in reaction rate. The maximum equilibrium yield of PMA is 78% when catalyst loading is 10 wt%. This indicates that the catalyst amount exerts an influence on the reaction rate, but not on the reaction equilibrium, which is well consistent with previous report [
50].
However, with a high catalyst amount of 12 wt%, the reaction rate is found to be lower than that observed with a 10 wt% catalyst loading. The reason for this phenomenon may be that as the catalyst loading increases, the catalyst particles aggregate, reducing the effective surface area and thereby decreasing the number of active sites that actually participate in the reaction, which lowers the reaction rate [
51]. Furthermore, the utilization of an excess of catalyst increases the cost of the reaction system. Consequently, a catalyst loading of 10 wt% is deemed to be the optimal catalyst amount for the esterification reaction between AA and PM.
The effect of initial molar ratio of PM to AA on the reaction was studied by varying the molar ratios of PM to AA from1:1 to 1:4, as shown in
Figure 3 with catalyst loading of 10 wt% and reaction temperature of 353 K. The results reveal that the conversion of PM significantly improves as the initial molar ratio of PM to AA increases from 1:1 to 1:3. Similar results have been observed in previous studies of esterification of benzyl acetate [
47]. Nevertheless, as the initial molar ratio of PM to AA continues to increase to 1:4, the increased trend of PM conversion becomes slower. This is due to the fact that within a certain range, an increase in the amount of AA results in an acceleration of collision frequency between reactant molecules, thereby increasing reaction rate. Furthermore, AA is also acted as a solvent to dilute the concentration of PM, which in turn results in a decrease in PM conversion. In consideration of subsequent separation issues, an excessively high concentration of AA would render separation more challenging, and consequently the optimal initial molar ratio of PM to AA is set at 1:3.
In order to investigate the effect of temperature on the reaction, the molar ratio of PM to AA was fixed to 1:3 and the catalyst loading was fixed to 10 wt%.
Figure 4 illustrates the relationship between reaction rate and temperature within the studied temperature range. As the reaction temperature increases from 333 to 363 K, the reaction rate accelerates, while the equilibrium yield of PMA remains relatively constant at different reaction temperatures. The experimental results indicate that the temperature has a more significant impact on the initial reaction rate than on the final reaction rate, which is consistent with previous reports [
13]. An increase in temperature facilitates the free movement of molecules, thereby enhancing the frequency of collisions between reactant molecules, which in turn leads to an increase in the reaction rate [
52]. Nevertheless, an increase in temperature also results in elevated energy consumption and safety concerns and 353 K is identified as the optimal reaction temperature.
Figure 5 illustrates that the initial reaction rate exhibits exponential growth with temperature. The calculation of the initial reaction rate is represented by
For every 10-degree increase in temperature, the initial reaction rate doubles. The substantial impact of temperature on the reaction rate suggests that the reaction is regulated by either internal diffusion or surface reaction. The result has demonstrated that the esterification reaction between PM and AA is not limited by internal diffusion as shown in
Figure 1. Consequently, the surface reaction is considered to be the limiting step of the esterification reaction.
3.3. Chemical Reaction Thermodynamic Equilibrium
In general, the non-ideality of liquid phase mixture necessitates the use of an activity-based model. In accordance with Equation (5), the activity
αi of component
i is proportional to its mole fraction
xi:
where
γi represents the activity coefficient of component
i. The activity coefficient approach is applicable to liquid mixture based on COSMO model. This method enables the prediction of interaction energies and activity coefficients of complex liquid systems without the need for experimental data. The COSMO-RS model is capable of calculating chemical potential of any solute in any pure or mixed solvent, thereby enabling prediction of thermodynamic properties such as activity coefficients and solubilities.
The activity coefficient is calculated by
where
μisol represents the chemical potential of solute
i in the solvent, and
μip represents the chemical potential of solute
i in the pure solute.
The chemical reaction for the esterification of AA and PM is represented by
This reaction is an acid-catalyzed esterification and is subject to thermodynamic equilibrium. The reaction equilibrium constant based on mole fractions (
Kx) is given by
The reaction equilibrium constant based on activities (
Kα) is predicted by
The calculated activity coefficients for each component corresponding to the experimental mole fraction at equilibrium within the temperature range of 333 to 363 K are listed in
Table 2. The values of
Kx and
Kα are calculated using Equations (8) and (9). According to the Van't Hoff equation, the relationship between the reaction equilibrium constant and temperature is given by
A linear fit was performed by the ln of calculated equilibrium constants
Kx and
Kα versus the inverse of experimental temperature values. The fitting results are shown in
Figure 6 and the calculated values of the reaction enthalpy change (Δ
rHθ) and reaction entropy change (Δ
rSθ) are presented in
Table 3:
The expressions relating
Kx and
Kα to temperature (T) are given by
The Gibbs free energy of the reaction can be calculated by
The standard enthalpy of the reaction is determined to be -11.97 kJ/mol (
Kα) based on activity-based calculations, while based on mole fraction calculations, the standard enthalpy of the reaction is determined to be -6.73 kJ/mol (
Kx). The reaction enthalpy based on activity calculation considers the intricate interactions between molecules in the solution, thereby enhancing the accuracy of the resulting data. Previous studies have indicated that the relationship between the equilibrium constant of the reaction and temperature is not particularly strong, suggesting a relatively low value for Δ
rH [
13,
53], which is consistent with our results. These results indicate that the influence of temperature on the initial reaction rate is more significant than its impact on the equilibrium conversion rate and the reaction is exothermal. A negative reaction entropy value indicates a reduction in the degree of chaos within the system. The standard Gibbs free energy of the reaction is calculated as -5.70 kJ/mol using Equation (13), indicating that the reaction is spontaneous, however the reaction couldn’t take place owing to the very slow reaction rate at standard state.
3.4. Reaction Kinetic Modelling
Both internal and external mass transfer resistances have been eliminated as shown in
Figure 1 and
Table 1, and thus the reaction rate is dependent on the adsorption of the reaction components on heterogeneous catalyst. The pseudo-homogeneous (PH), Eley-Rideal (ER), and Langmuir-Hinshelwood-Hougen- Watson (LHHW) kinetic models are frequently employed for correlating kinetic data pertaining to esterification reactions.
The PH model is widely applied in esterification systems, where the adsorption and desorption of all components can be neglected [
52,
54,
55,
56,
57,
58]. The PH model assumes that the catalyst swells completely upon contact with a polar solvent, and the cation exchange resin is equivalent to a liquid acid center, treating the entire reaction system as a homogeneous phase. Both the LHHW and ER models are suitable and applicable for multiphase catalytic reactions when the surface reaction is the controlling step. The LHHW model is effective in describing surface reactions between adsorbed molecules, while the ER model is well-suited to describe surface reactions between an adsorbed substance and a free substance in the liquid phase.
The esterification reaction between AA and PM is reversible and an excess amount of AA is added in order to enhance the conversion of PM. Consequently, the reaction rate is expressed as the consumption rate of PM. The formulations for the PH, ER, and LHHW models are presented in Equations (14)–(16):
where
CPM,
CAA,
CPMA, and
CH2O are molar concentrations of PM, AA, PMA, and H
2O, respectively.
Kx is the reaction equilibrium constant based on mole fractions,
Ki represents the adsorption equilibrium constant of component
i, and
k+ is the rate constant of the forward reaction.
In consideration of the non-ideality of the liquid phase, the activity-based kinetic models are represented by Equations (17-19):
where α
PM, α
AA, α
PMA, and α
H2O represent the activities of PM, AA, PMA, and H
2O, respectively, and
Kα is the reaction equilibrium constant based on activities.
The adsorption equilibrium amount (
qe, mg/g) of each component on the solid acid catalyst is calculated according to Equation (20):
where
C0 and
Ce (g/L) represent the mass concentrations of the solution before adsorption and at equilibrium, respectively,
V (L) is the volume of the solution, and
m (g) is the mass of the catalyst.
The Langmuir adsorption isotherm model is employed with relevant expression provided by Equation (21):
where
Ki is the adsorption equilibrium constant,
Ce (g/L) is the mass concentration of the solution at adsorption equilibrium, and
qm (g/g) represents the theoretical maximum adsorption capacity of the solid acid catalyst.
According to the Arrhenius equation, the relationship between
k+ and reaction temperature (
T) is given by Equation (22):
where
k0+ is the pre-exponential factor of the reaction,
Ea+ is the activation energy of the reaction, and R is the gas constant.
As both the ER model and LHHW model involve the adsorption of components from the liquid phase onto solid acid catalysts, adsorption experiments are conducted as a preliminary step. The Langmuir adsorption isotherm model is employed, and its expression is given by Equation (20). The
qm of the solid acid catalyst and
Ki obtained from the Langmuir model are presented in
Table 4.
The experimentally obtained adsorption equilibrium constants exhibit considerable error, rendering them unsuitable for quantitative analysis. They can, however, be employed as qualitative references. Consequently, these parameter values are employed as initial values for the fitting calculations of the kinetic models, rather than being directly utilized as the adsorption equilibrium constant terms in the ER and LHHW models.
Python is a high-level programming language that is widely used in scientific computing and data analysis. The Python 3.8 programming language was employed to fit the kinetic models, with the kinetic parameters and error indicators presented in
Table 5. Although all models exhibit similar values for root mean square error (RMSE) and coefficient of determination (
R2), the LHHW model has the smallest mean absolute error (MAE). Consequently, among the three models employed, the LHHW model exhibits the most favorable correlation. The parity plot for the experimental and predicted rate of reaction is shown in
Figure 7, indicating that the predicted concentration values of the three models are in good agreement with the experimental values.
According to the fitting results of the LHHW model, the apparent activation energy for the esterification reaction between AA and PM catalyzed by Amberlyst-35 is determined to be 62.0 kJ/mol. This result is in close agreement with the reported value of 60.5 kJ/mol for the forward reaction activation energy by Wang B
et al. [
14]. The satisfactory correlation between the experimental data and LHHW model suggests that the reaction is governed by surface reaction, which is in accordance with the findings in
Section 3.2 regarding the impact of temperature on the esterification reaction. According to the LHHW model, PM and AA are independently adsorbed on the catalyst surface, after which a surface reaction occurs to form PMA. Finally, PMA is desorbed and diffuses into the liquid phase.