The continuous flow synthesis of ibuprofen is simulated taking into
account the main process modelling issues. The most appropriate
thermodynamic models were revised to account for the properties of the
unconventional reactants and complex molecules. Furthermore, in some
reaction steps ionic properties may be needed rather than those of the
neutral molecules. All these points need a careful optimisation of the
methods for the estimation of the properties, with possible huge
discrepancies of the results. The products separation and purification
steps in continuous mode was also added, but, again, the key issue is
the correct selection of the thermodynamic package, relying on very
complex cases where experimental equilibrium data are missing. Improper
previsions can neglect important issues, such as the unpredicted
precipitation of salts, not predicted during the simulation, but
observed experimentally by us