Continuously running microreaction technology offers novel ways of process intensification, going beyond its established features such as process safety or modularity. One current concept is to operate under rough reaction conditions to speed up conversion rates. Performing microprocess technology under rigorous reaction conditions for several applications and under utilization of different techniques is currently investigated within the German research cluster called "Novel Process Windows". Due to the improvements obtained in synthesis performance, a positive effect on environmental impacts is expected as well. But, harsh process conditions probably require added energy input and effort concerning process control and safety. The question whether the ratio of effort and benefit is less than for alternative approaches or not can be addressed by (Simplified) Life Cycle Assessment. Such analyses will be particularly helpful, if they are already integrated into the design of the process, in order to disclose the key drivers of a deliberated design of a green chemical process.
Continuously running syntheses in microstructured reactors offers novel ways to intensify conventional chemical processes. An outstanding advantage of microreaction technology is the high surface-to-volume-ratio which enables intensive mixing phenomena as well as high mass and heat transfer rates. Thus, microstructured reactors may be a suitable means to improve multiphase reactions by increasing the interfacial area and the intensification of internal mixing. This improvement in reaction performances may lead to reduced environmental burdens of the process under consideration. The method of simplified life cycle assessment (SLCA) is a suitable tool to evaluate the environmental burdens caused by chemical processes. It has been applied already in research and development to identify the key parameters for a deliberate green process design of two biphasic reactions, the esterification of phenol and benzoyl chloride resulting in phenyl benzoate and the synthesis of one of the corresponding phase transfer catalysts, [BMIM]Cl. Further, SLCA is complemented by a simple cost estimation to investigate the main cost drivers relevant for possible industrial application of the syntheses investigated.
The activation of relatively inert carbon dioxide as a building block for organic products is of interest from both ecological and chemical points of view. One of the few industrially relevant processes using CO 2 is the Kolbe-Schmitt synthesis. Two strategies to obtain the carboxylated product 2,4-dihydroxybenzoic acid from resorcinol are presented: both Dimcarb and hydrogencarbonate-or methylcarbonate-based ionic liquids are employed as reactive solvents in a microwaveassisted reaction. Reaction optimization shows that the ionic liquids are more reactive than Dimcarb. However, Dimcarb offers advantages with regard to ecological aspects, such as the Global Warming and Human Toxicity Potential and the Cumulative Energy Demand, which were assessed as part of the process development.
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