Micro-reactor mixing unit interspacing for fast liquid-liquid reactions leading to a generalized scale-up methodology

Mielke, Eric; Plouffe, Patrick; Mongeon, Sébastien S.; Aellig, Christof; Filliger, Sarah; Macchi, Arturo; Roberge, Dominique M.

doi:10.1016/j.cej.2018.07.043

Cited by 29 publications

(22 citation statements)

References 46 publications

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“…Similarly, for multiphase liquid‐liquid systems, Plouffe et al scaled‐up a channel of continuous LL mixing units and showed the crossover scale to commercial static mixers by operating in the drop flow regime where the interphase mass transfer coefficient was again correlated to the energy dissipation rate. In this case, a maximum reaction conversion and hence optimum energy dissipation rate is obtained where the gain in interfacial area via drop break‐up for mass transfer no longer overcomes the loss in residence time since the droplets approach the Kolmogorov length scale . An algorithm for scale‐up was then explicitly presented for operation at this optimum condition.…”

Section: Technical Challenges Uncertainty and Limitations To Micro‐mentioning

confidence: 99%

Experimental methods in chemical engineering: Micro‐reactors

et al. 2019

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Whereas the bulk chemical industry has historically sought economic advantage through economies of scale, a paradigm shift has researchers developing systems on smaller scales. Nano-cages and nano-actuators increase selectivity and robustness at the molecular scale. In parallel, micro-contactors with sub-millimetre lateral dimensions are decreasing boundary layers that restrict heat and mass transfer and thus meet the objectives of process intensification with great increases in productivity with a smaller footprint. These contactors continue to serve chemical engineers and chemists to synthesize fine chemicals and characterize catalysts; however, they have now been adopted for sensors in biological and biochemical systems. A bibliometric analysis of articles indexed in the Web of Science in 2016 and 2017 identified five major clusters of research: catalysis and bulk chemicals; nanoparticles; organic synthesis and flow chemistry; systems and micro-fluidics applied to biochemistry; and micro-channel reactors and mass transfer. In the early 1990s, less than 100 articles a year mentioned micro-reactors, while over 943 articles mentioned it in 2017. Here, we introduce micro-reactors and their role in the continuous synthesis of fine chemicals across the various scales to commercialization.

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Section: Technical Challenges Uncertainty and Limitations To Micro‐mentioning

confidence: 99%

Experimental methods in chemical engineering: Micro‐reactors

et al. 2019

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“…As such, the effectiveness of the LLM as a venturi‐like split‐and‐recombine micromixer, particularly for undertaking fast single‐phase reactions, was sought. [ 5,6,10–12 ]…”

Section: Introductionmentioning

confidence: 99%

Computational fluid dynamics simulation of pressure drop and macromixing in LL microreactors

et al. 2021

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A computational fluid dynamics (CFD) model was developed to simulate single‐phase flow in LL microreactors using the open‐source software OpenFOAM. The k‐ω SSTLM turbulence model was implemented to account for the impact of small‐scale temporal and spatial fluctuations that emerge in the base LL mixing module (LLM) on the flow field and transport of a passive scalar. The CFD model was successfully validated based on excellent conformance to experimental pressure loss (R2 > 0.997) and residence time distribution (RTD) data (R2 > 0.97) at flow rates ranging from 10‐100 g/min. Streamlines, velocity, pressure, and turbulent viscosity profiles were mapped across the 3D domain of repeating reactor segments to analyze local fluid dynamics. In a continuous series of LLMs, the flow field becomes fully developed after the second module. A drastic change in flow behaviour in the LLM was identified at 30 g/min (Re = 643) based on the emergence of advective recirculation zones and significant turbulent dispersion. Recirculation zones in the LLM grow larger from 20‐50 g/min and are equal in size from 50‐100 g/min. Four LL reactor plates with differing configurations of spacing between LLMs were compared extensively by analyzing pressure drop and RTD. Plates with continuous or equally‐spaced LLMs demonstrated a near plug‐flow profile with minor dispersion (Pe > 100), albeit at a greater power dissipation. Plates with longer residence‐time channels between LLMs yielded a broader and right‐skewed RTD due to the intermittent attenuation of chaotic flow patterns.

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“…In general, it can make full use of its advantages at the time when catalytic reaction shifts to a micro‐scale fluidized bed reactor 18,19 . Firstly, there is a massive contact area between the liquid phase and the solid phase, which may contribute to the heterogeneous reaction and improve the intensity of production.…”

Section: Introductionmentioning

confidence: 99%

Catalytic hydrolysis of alkaline sodium borohydride solution for hydrogen evolution in a micro‐scale fluidized bed reactor

Zhang

Cheng

et al. 2020

Int J Energy Res

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Summary An investigation was conducted into the generation of hydrogen from catalytic hydrolysis of alkaline sodium borohydride solution in a micro‐scale fluidized bed. In this work, the Cobalt loaded on walnut shell activated carbon was applied as the catalyst. The impact of NaBH4 concentration, the diameter of catalyst particle, the rate of reaction fluid flow, and the temperature of initial reaction fluid on the process of hydrogen generation was explored, and the optimum reaction conditions were determined. It was found out that the maximum length of stable hydrogen generation (58.46% of the total reaction time) is obtainable under the following conditions. The concentration of NaBH4 is 2 wt%, the flow rate is 3.00 × 10−3 m·s−1, and the flow temperature is 25°C. In addition, a comparison was performed between the batch reactor and micro‐fluidized bed reactor during the process of hydrogen generation. Moreover, when the concentration of NaBH4 reached 1 and 2 wt%, the efficiency and stability of the micro‐fluidized bed reactor were identified as superior to those of the batch reactor.

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Micro-reactor mixing unit interspacing for fast liquid-liquid reactions leading to a generalized scale-up methodology

Cited by 29 publications

References 46 publications

Experimental methods in chemical engineering: Micro‐reactors

Experimental methods in chemical engineering: Micro‐reactors

Computational fluid dynamics simulation of pressure drop and macromixing in LL microreactors

Catalytic hydrolysis of alkaline sodium borohydride solution for hydrogen evolution in a micro‐scale fluidized bed reactor

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