Potential Analysis of Smart Flow Processing and Micro Process Technology for Fastening Process Development: Use of Chemistry and Process Design as Intensification Fields

Abstract

Flow processes with microstructured reactors allow paradigm changes in process development and thus can enable a faster development time to the final production plant. They do this by exploiting similarity effects along the development chain (modularity) and intensification. The final result can be a (significantly) reduced number of apparatus in the plant, a (significantly) reduced apparatus size, and a higher predictability in the scale-out of the apparatus. So far, this was mainly achieved via transport intensification given in microstructured reactorsimproved mixing and heat transfer which increase productivity and possibly improve selectivity. A more new idea is chemical intensification through deliberate use of harsh chemistries at unusual (high) pressure, temperature, concentration, and reaction environment which again increases productivity. A very new idea is the process design intensification -the reaction-maximized flow processes need less separation expenditure and the small unit size together with the high degree in functionality gives large potential for system integration. Both means change and simplify the process scheme totally which can lead to a reduced number of apparatus and has impact on predictability. The modular nature of the small flow units allow an easy implementation to modern modular plant environments (Future Factories) which enables to perform all the testing cycles (lab, pilot, production) in one plant environment; an example are here container plants. All these measures have large potential for (much) decreased overall development time.

Beyond Organometallic Flow Chemistry: The Principles Behind the Use of Continuous-Flow Reactors for Synthesis

“…This concept of using unusual reaction conditions is also called Novel Process Windows, coined by Hessel. [12][13][14] The use of microreactor technology further provides enhanced process safety, high control over the reaction conditions, and increasing throughput by controlled scalability. According to a detailed investigation of Roberge et al, 50% of the reactions in the 4 pharmaceutical and fine chemical industry could benefit from a continuous process.…”

The Claisen Rearrangement – Part 2: Impact Factor Analysis of the Claisen Rearrangement, in Batch and in Flow

“…More and more chemists were attracted by the new synthesis tool since they discovered that it opens doors to new chemistries, in particular under harsh conditions. Novel process windows widened the synthetic possibilities and toolbox of the chemists [68][69][70][71]; adding chemical intensification to the prior developed transfer intensification. The term flow chemistry emerged.…”

“…Microreactors commonly facilitate the use of such alternative activation for a number of reasons and indeed such novel process windows were tested in flow [68][69][70][71]. The use of the microreactor or microfluidics concept might be considered as the simplest way to solve the shortcomings of the existing industrial realization of the Claisen-like processes [64-67, 80, 81].…”

Evaluation of Diffusion Coefficient Determination using a Microfluidic Device

“…This holds true for microreactor technology, where diminished diffusion times related to small channel dimensions often lead to process intensification. 1 While laminar flow indicated by the low Reynolds numbers provides a carefully controlled environment where convective mass transfer occurs in the direction of the fluid flow, mixing in microchannels can be achieved solely by molecular diffusion. 2 Quantitative analysis of diffusion is therefore a necessity for the efficient design and optimization of nearly all processes in microfluidic devices, while accurate determination of diffusion coefficients represents a very important step in understanding and modeling transport phenomena that take place in the chosen system.…”