Intensified alternative for sustainable gamma-valerolactone production from levulinic acid

γ-Valerolactone (GVL) is a promising bio-based chemical with applications in renewable fuels and chemicals. While several catalytic strategies for its production exist, a common challenge is the lack of an integrated process that combines both production and purification. Currently, these steps are performed separately, with distillation being energy-intensive, especially at low yields. This study presents a novel approach by integrating both production and purification of GVL in a single, energy-efficient operation using reactive distillation.The novelty of this work lies in the design and optimization of a reactive distillation column, where key operating conditions and design parameters are carefully selected to ensure that both chemical reactions and component purification occur efficiently within the same unit. Experimental data from the literature were used to model the process kinetics, ensuring the simulation accurately reflects experimental conditions. This integrated approach not only reduces energy consumption but also improves the overall efficiency of GVL production, offering a more sustainable and cost-effective alternative for industrial applications. By employing a multiobjective optimization framework, the design balances economic, environmental, and operational objectives, achieving a reduction in total annual cost (TAC) to 43 % and environmental impact (Eco Indicator 99, EI99) to 45 % of the values associated with conventional processes. Moreover, energy consumption is decreased by 63 %, and GVL production is increased by 25 %, demonstrating the significant potential of reactive distillation for improving both efficiency and sustainability. • Integration of GVL production and purification in one reactive distillation column, reducing energy consumption. • First use of reactive distillation to simultaneously produce and purify γ-valerolactone (GVL), filling a key gap. • Optimization of process variables like reflux ratio and flow rates to enhance GVL production efficiency and sustainability. • Experimental data from literature used to derive kinetic parameters for accurate and realistic simulation modeling.