Process intensification for continuous synthesis of performic acid using Corning advanced-flow reactors

The present paper reports the experimental details for the synthesis of performic acid (PFA) using Corning advanced-flow reactors (AFRs) using formic acid and H₂O₂ as reactants, and sulfuric acid as homogeneous catalyst. The effect of different operating parameters on PFA concentration such as reactant flow rates (residence time), temperature, reactant and catalyst concentration were studied. The experimental results indicate that the heart-shaped pellet structure in AFR provides better mixing, and hence more conversion with less residence time achieved. Moreover, AFR technology offers the possibility to conduct chemical reactions in a more sustainable way due to miniaturization and increased safety. Reactions show optimum results at 30°C with a feed flow rate of 80 ml/h in the presence of 1 w/w % H₂SO₄ as catalyst. The optimized results demonstrated the capability of AFR technology for enhancement in the formation of PFA (time equal to 1 min) with high conversion (95.85%). Further, it has been found that the concentration of PFA was reached at maximum value within 1 min of time. Therefore, the production of PFA is very fast in a microreactor, which saves our time and energy and in turn it saves the environment on fuel requirement and therefore this process is green.