Scaled-Up Production of Graphene Oxide: Design, Simulation, and Analysis of a Stirred Tank Batch Reactor

Graphene oxide (GO) is an emerging product experiencing exponential growth in popularity and demand. This comprehensive research evaluates the technical and economic feasibility of implementing a large-scale GO production plant in Malaysia, based on existing pilot-scale data from the industry. The major aspect of the GO production process is the GO synthesis reaction, carried out in a jacketed, stirred tank batch reactor of approximately 500 L capacity. Computational Fluid Dynamics (CFD) software COMSOL Multiphysics is used to simulate the dynamic behaviour of reactants within the reactor to obtain the best possible configurations and dimensions of the reactor. The results indicated that the reactor should have a height-to-diameter (H/D) ratio of 1.75, with an inner diameter of 0.71 m and a total height of 1.63 m. The entire proposed production process is simulated using SuperPro Designer software, and the results obtained are used to aid in the plant's equipment sizing calculations and economic analysis. A comprehensive economic analysis has assessed its profitability and economic viability. All calculations indicate that the plant would be a potentially profitable venture with a high return on investment (ROI) of 126.9% and a short payback period of 0.83 years.