A review on microreactors: Reactor fabrication, design, and cutting-edge applications

Suryawanshi, Prashant L.; Gumfekar, Sarang P.; Bhanvase, Bharat A.; Sonawane, Shirish H.; Pimplapure, Makarand S.

doi:10.1016/j.ces.2018.03.026

Cited by 227 publications

(114 citation statements)

References 189 publications

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“…A premixed methane and either air or oxygen mixture is fed to the reactor, after the reactant stream is preheated to a desired temperature. The reactor contains multiple parallel channels having sub-millimeter dimensions, thus offering advantages from enhanced heat and mass transfer [61]. The reactor modeled in this paper is shown schematically in Figure 1.…”

Section: Reaction Systemmentioning

confidence: 99%

RETRACTED: Computational Fluid Dynamics Modeling of the Catalytic Partial Oxidation of Methane in Microchannel Reactors for Synthesis Gas Production

Chen

Song

2018

Processes

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This paper addresses the issues related to the favorable operating conditions for the small-scale production of synthesis gas from the catalytic partial oxidation of methane over rhodium. Numerical simulations were performed by means of computational fluid dynamics to explore the key factors influencing the yield of synthesis gas. The effect of mixture composition, pressure, preheating temperature, and reactor dimension was evaluated to identify conditions that favor a high yield of synthesis gas. The relative importance of heterogeneous and homogenous reaction pathways in determining the distribution of reaction products was investigated. The results indicated that there is competition between the partial and total oxidation reactions occurring in the system, which is responsible for the distribution of reaction products. The contribution of heterogeneous and homogeneous reaction pathways depends upon process conditions. The temperature and pressure play an important role in determining the fuel conversion and the synthesis gas yield. Undesired homogeneous reactions are favored in large reactors, and at high temperatures and pressures, whereas desired heterogeneous reactions are favored in small reactors, and at low temperatures and pressures. At atmospheric pressure, the selectivity to synthesis gas is higher than 98% at preheating temperatures above 900 K when oxygen is used as the oxidant. At pressures below 1.0 MPa, alteration of the dimension in the range of 0.3 and 1.5 mm does not result in significant difference in reactor performance, if made at constant inlet flow velocities. Air shows great promise as the oxidant, especially at industrially relevant pressure 3.0 MPa, thereby effectively inhibiting the initiation of undesired homogeneous reactions.

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Section: Reaction Systemmentioning

confidence: 99%

RETRACTED: Computational Fluid Dynamics Modeling of the Catalytic Partial Oxidation of Methane in Microchannel Reactors for Synthesis Gas Production

Chen

Song

2018

Processes

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“…(12), in which the model parameter (m) is also related to the shape of the radial velocity profile, as described by Eqs. (12) and (13) [26].…”

Section: Residence Time Distribution Modelsmentioning

confidence: 99%

Residence Time Distribution of a Capillary Microreactor Used for Pharmaceutical Synthesis

et al. 2020

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The main drivers for application of small‐scale reactors in the pharmaceutical industry are the possibility of rapid synthesis and screening of novel drugs as well as the readiness of the scale‐up. The characterization of fluid flow pattern was performed through step‐up and step‐down residence time distribution experiments using a tracer at six different flow rates. Four single‐parameter models were considered for representing deviations from ideal plug flow and ideal laminar flow in tubes. The model that provided the best results was the axial dispersion model and the Peclet and Reynolds numbers could be well correlated. Obtained Peclet values from 44 to 244 were close to Pe > 100, in which axial dispersion can be neglected and the reactor can be considered as plug flow reactor.

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“…In MRT, the reactions occur under microfluidic conditions within microchannels , in devices with sizes normally on the order of 100 μm, the volumes of which cover the range from microliters to milliliters , , . Owing to the small size, the flow is mainly laminar, which promotes homogenization only by diffusion, making contact among molecules easier . Accordingly, the reaction conditions are uniform, and all molecules pass with the same mean residence time and temperature .…”

Section: Introductionmentioning

confidence: 99%

“…Accordingly, the reaction conditions are uniform, and all molecules pass with the same mean residence time and temperature . Owing to the high surface/volume ratio, MRT offers several advantages over the batch process, including (a) easier temperature and pressure control, (b) more efficient diffusion of molecules, (c) higher reaction rate, (d) higher conversion and selectivity, (e) safer operation, (f) less waste generation, (g) higher product purity, and (h) better reliability and reproducibility , , . Thus, MRT has gained attention from academics as well as the chemical and pharmaceutical industries, and research in this area has been increasing exponentially , , , .…”

Section: Introductionmentioning

confidence: 99%

“…Owing to the high surface/volume ratio, MRT offers several advantages over the batch process, including (a) easier temperature and pressure control, (b) more efficient diffusion of molecules, (c) higher reaction rate, (d) higher conversion and selectivity, (e) safer operation, (f) less waste generation, (g) higher product purity, and (h) better reliability and reproducibility , , . Thus, MRT has gained attention from academics as well as the chemical and pharmaceutical industries, and research in this area has been increasing exponentially , , , . Our proposal is to replace the current scale‐up in drug development with the numbering‐up approach, i.e., increasing the number of microreactors in parallel and then reducing the time required for compounds to reach the production line , .…”

Section: Introductionmentioning

confidence: 99%

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Microreactor Technology as a Tool for the Synthesis of a Glitazone Drug Intermediate

et al. 2018

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One of the bottlenecks in the pharmaceutical industry is drug production scaleup, which can be performed by microreactor technology. Such an approach was applied to the synthesis of (Z)-5-(4-hydroxybenzylidene)thiazolidine-2,4-dione, a bioactive aromatic heterocyclic compound belonging to the class of glitazones. n-Propanol was the best solvent and piperidine the best catalyst for the batch reaction, which was completed in only 5.5 h. In the microreactor, the productivity was almost independent of solvent. The microreactor behaved as a plug-flow reactor and operated at a steady state for ten hours without efficiency loss. The results suggest that microreactors may replace batch reactors in scaling up drug production.

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A review on microreactors: Reactor fabrication, design, and cutting-edge applications

Cited by 227 publications

References 189 publications

RETRACTED: Computational Fluid Dynamics Modeling of the Catalytic Partial Oxidation of Methane in Microchannel Reactors for Synthesis Gas Production

RETRACTED: Computational Fluid Dynamics Modeling of the Catalytic Partial Oxidation of Methane in Microchannel Reactors for Synthesis Gas Production

Residence Time Distribution of a Capillary Microreactor Used for Pharmaceutical Synthesis

Microreactor Technology as a Tool for the Synthesis of a Glitazone Drug Intermediate

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