Continuous Counter-Current Ionic Liquid Metathesis in Mixer-Settlers: Efficiency Analysis and Comparison with Batch Operation

[Image: see text] Following the initial cation formation, the synthesis of ionic liquids (ILs) often involves an anion-exchange or metathesis reaction. For hydrophobic ILs, this is generally performed through several cross-current contacts of the IL with a fresh salt solution of the desired anion. However, if a large number of contacts is required to attain an adequate conversion, this procedure is not economical because of the large excess of the reagent that is consumed. In this study, the metathesis of an IL, Aliquat 336 or [A336][Cl], to ILs with other anions ([A336][X] with X = HSO(4)(–), Br(–), NO(3)(–), I(–), and SCN(–)) was studied in a continuous counter-current mixer-settler setup. McCabe–Thiele diagrams were constructed to estimate the required number of stages for quantitative conversion. Significantly higher IL conversions were achieved, combined with reduced reagent consumption and waste production. This improvement in efficiency was most pronounced for anions placed low in the Hofmeister series, for example, HSO(4)(–), Br(–), and NO(3)(–), which are difficult to exchange. The performance of the counter-current experiments was compared with the conventional multistep cross-current batch process by calculating the reaction mass efficiency (RME) and the environmental factor (E-factor). The RMEs of the cross-current experiments were notably smaller, that is, 38–78% of the values observed for the counter-current experiments. The E-factors of the counter-current experiments were a factor of 2.0–6.8 smaller than those of the cross-current experiments. These sustainability metrics indicate a highly efficient reagent use and a considerable, simultaneous decrease in waste production for the counter-current IL metathesis reactions.