Glycidyl methacrylate (annual production of 1,000 tons) project

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I. Project Positioning The core product of this project, glycidyl methacrylate (GMA), is a special bifunctional monomer of the acrylate family; thanks to its unique molecular structure, it plays a key role in various fields. As a key ingredient in powder coatings, it can significantly enhance the hardness, weather resistance, and adhesion of the coating ； Its applications in areas such as thermosetting coatings, fiber treatment agents, and adhesives also provide significant support for optimizing product performance, resulting in sustained strong market demand. II. Basic Product Information
Category Details:
Chinese Name: Glycidyl methacrylate
English Name: Glycidyl methacrylate
Alternative Names: 2,3-Epoxypropanemethacrylate, Methyl acrylate epoxide, Glycidyl methacrylate
Chemical Formula: C₇H₁₀O₃
Molecular Weight: 142.15
Melting Point: -82°C
Boiling Point: 189°C
Water Solubility: Insoluble in water
Density: 1.042 (unit to be specified, e.g., g/cm³)
Appearance: Colorless transparent liquid
Flash Point: 76°C
Safety Profile: Slightly toxic
Hazard Label: Toxic and harmful

III. Analysis of Synthesis Process
(A) Selection of Synthetic Route
There are two possible routes for the synthesis of GMA: the reaction of sodium methacrylate with epichlorohydrin, and the transesterification of methyl methacrylate with epichlorohydrin. This project chooses the former because its raw materials are widely available (methyl acrylate, epichlorohydrin, sodium hydroxide, etc. are all basic chemical raw materials), and the reaction conditions are mild, making it suitable for industrial production. (II) Detailed process flow 1. Preparation of sodium methacrylate: In a four-necked reaction vessel equipped with a stirrer, a reflux condenser, a thermometer, and a dropper funnel, 1000 L of methacrylic acid and 1000 L of solvent (an inert solvent such as toluene is commonly used to ensure stability of the reaction system) are first poured in, and the mixture is stirred thoroughly. Subsequently, 103.5 kg of a 50% aqueous NaOH solution was added slowly, with the reaction temperature being strictly controlled below 55°C to prevent intense reactions that could lead to safety risks and side reactions. After the addition is complete, continue stirring for 30 minutes to ensure full reaction. 0.2 kg of p-hydroxyanisole was added as a polymerization inhibitor to prevent the self-polymerization of methacrylic acid; thereafter, dehydration under reduced pressure at 85–90°C and 30.7–36.0 KPa was carried out to produce the sodium methacrylate salt, which was then stored sealed. 2. The synthesis of GMA was carried out in a three-necked flask, in which 40 kg of dried sodium methacrylate, 0.2 kg of p-hydroxyanisole, 1.2 kg of quaternary ammonium salt catalysts such as triethylbenzylammonium chloride, and 250 kg of epichlorohydrin were added sequentially. The reaction temperature was maintained at 105 – 110°C, and the reaction proceeded for 3 hours; during this time, the water generated as a byproduct of the reaction was promptly separated using a water separator to facilitate the forward progression of the reaction. After the reaction is complete, the resulting NaCl is removed by filtration. The filtrate is first subjected to vacuum distillation at 80–85°C and 6.7–8.0 KPa to recover epichlorohydrin, and then distilled and purified under conditions of 100–105°C and 1.1–1.6 KPa to obtain the GMA product. (III) Raw material consumption metrics: To produce 1 ton of GMA, 780 kg of methacrylic acid, 690 kg of epichlorohydrin, and 330 kg of sodium hydroxide are required. IV. Equipment investment plan: The total estimated investment in equipment for this project is 10 million yuan; the detailed list of equipment will be determined once the project is launched. It mainly includes: 1. Reaction equipment: specialized reactors such as four-port flasks and three-port flasks, to meet the requirements of reactions at different stages ； 2. Separation equipment: filters, distillation towers, etc., for solid-liquid separation and product purification ； 3. Auxiliary equipment: stirrers, condensers, thermometers, water separators, etc., to ensure the smooth progress of the reaction ； 4. Safety and environmental protection equipment: exhaust gas treatment systems, wastewater pretreatment equipment, etc., to ensure that production meets environmental requirements. V. Waste Management and Risk Control (I) Generation and Treatment of Waste 1. Solid waste: Primarily sodium chloride produced as a by-product of the reactions; it needs to be collected centrally and handed over to specialized agencies for harmless treatment or comprehensive utilization, in order to prevent contamination of soil and water bodies. 2. Waste gases: These include organic waste gases such as unreacted methacrylic acid, epichlorohydrin, and solvent volatiles. A treatment process combining condensation recovery, activated carbon adsorption, and catalytic combustion is planned to be used for treating these gases before they are released, ensuring that they meet the required standards. 3. Wastewater: The wastewater generated from equipment cleaning and floor washing is subjected to pretreatment processes such as neutralization and sedimentation before being fed into the plant’s wastewater treatment system for further treatment. (II) Hazard analysis of production 1. Risk of explosive polymerization: Methyl acrylate has polymerization properties; if the temperature during production gets out of control, insufficient amount of inhibitor is added, or mixing is interrupted, explosive polymerization may occur, leading to overpressure in the equipment, material leakage, and even explosions. A real-time monitoring system for temperature and pressure must be installed, emergency cooling and pressure relief devices must be provided, and the process of adding inhibitors must be strictly regulated. 2. Fire and explosion risk: Methyl acrylate, epichlorohydrin, and solvents are all flammable substances, and their vapors mixed with air can form explosive mixtures. The production workshop must maintain good ventilation; open flames are strictly prohibited, explosion-proof electrical equipment should be used, and gas detection alarms must be installed. 3. Toxicological hazards: GMA and some of its raw materials are toxic; long-term exposure or inhalation of their vapors may harm human health. Operators must be equipped with protective gear, the workshop should have a ventilation and exhaust system, and regular occupational health check-ups should be conducted. Chemical Engineering Discussions