The
liquid–liquid phase-transfer-catalyzed (PTC) Wittig
reaction is a green and sustainable method to access alkenes from
ketones or aldehydes, which consists of immiscible two liquid phases
with reactions in both phases. Its conventional batchwise synthesis
in stirred reactors is severely limited by a low mass transfer rate
resulting from poorly defined liquid–liquid interfacial area
and drop size control difficulties. In this work, this biphasic reaction
in microchannels under the slug-flow pattern was experimentally and
numerically studied. The influences of channel size and a range of
operating parameters on the specific interfacial area, extraction
efficiency, volumetric mass transfer coefficient, and conversion of
this biphasic reaction at various operating conditions were thoroughly
investigated. The results revealed that the specific interfacial area,
extraction efficiency, and volumetric mass transfer coefficient decreased
with channel size. For a fixed channel length, the extraction efficiency
decreased with mixture flow velocity. When the residence time was
kept constant, the volumetric mass transfer coefficient increased
as the mixture flow velocity increased. The conversion increased with
decreasing size of the channel, and it augmented with mixture flow
velocity and aqueous-to-organic phase flow ratio as well. A CFD model
coupling the two-way mass transfer and the two reactions was developed
and well validated against the relevant experimental data, which enabled
a better understanding of the spatiotemporal variation mechanism of
this biphasic reaction on the microscale. The results presented would
be helpful for the developments of industrial applications of microchannel-based
PTC Wittig reactions with improved performance.