The spinning mesh disc reactor (SMDR) is a novel process intensification technology which uses centrifugal force to drive reaction fluid over a mesh supported catalyst on a rotating disc. The potential of the SMDR for organic synthesis has been demonstrated for the first time for Henry reaction using copper immobilised on woollen cloth mesh. A new protocol for copper immobilisation on wool has been developed producing a superior catalyst to the homogeneous copper triflate system: copper heterogenised on wool afforded a higher batch conversion (85%) (cf. 57% for the homogeneous case) in the same timeframe. In the SMDR, the reaction was more efficient than either homogeneous or heterogeneous batch reaction: with further optimisation the conversion increased from 77% to 93% as the spinning speed of the disc increased from 250 to 450 RPM at a flowrate of 3 ml s-1. There was only a 3% reduction in conversion on re-use of copper wool over 3 cycles under similar experimental conditions indicating that this catalyst is robust. Pure wool was also found to have some catalytic activity for the Henry reaction, giving a maximum conversion of 85% at 450 RPM in the SMDR. However, it deactivated significantly with reuse and therefore cannot be considered a stable, robust catalyst. Overall, the results show that the copper immobilised wool in the SMDR can be used to improve the conversions for the Henry reaction and that there is therefore promise for the SMDR to be extended to other traditional solvent based reactions.
With stringent environmental regulations and a new drive for sustainable manufacturing, there is an unprecedented opportunity to incorporate novel manufacturing techniques. Recent political and pandemic events have shown the vulnerability to supply chains, highlighting the need for localised manufacturing capabilities to better respond flexibly to national demand. In this paper, we have used the spinning mesh disc reactor (SMDR) as a case study to demonstrate the path forward for manufacturing in the post-Covid world. The SMDR uses centrifugal force to allow the spread of thin film across the spinning disc which has a cloth with immobilised catalyst. The modularity of the design combined with the flexibility to perform a range of chemical reactions in a single equipment is an opportunity towards sustainable manufacturing. A global approach to market research allowed us to identify sectors within the chemical industry interested in novel reactor designs. The drivers for implementing change were identified as low capital cost, flexible operation and consistent product quality. Barriers include cost of change (regulatory and capital costs), limited technical awareness, safety concerns and lack of motivation towards change. Finally, applying the key features of a Sustainable Business Model (SBM) to SMDR, we show the strengths and opportunities for SMDR to align with an SBM allowing for a low-cost, sustainable and regenerative system of chemical manufacturing.
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