Continuous Reactor Technology for Ketal Formation:  An Improved Synthesis of Solketal

The development of a fully continuous process for the synthesis of solketal (4-hydroxymethyl-2,2-dimethyl-1,3-dioxolane) is described. The use of a heterogeneous catalyst, recycle of unreacted starting material, elimination of the need for an entraining solvent, and purification of the product in situ all afford improvements over existing processes. Data generated in model reactions is used to prove the applicability of the process to a counter-current distillation reactor design, and to compute the operating parameters of the reactor.