(130g) Modular Micro Process Technology - New Devices and Applications

Micro process technology opens new pathways for the development of economical, innovative and intensified processes. In the chemical and pharmaceutical industry, this technology plays an increasingly important role in research, development and production because of its decisive advantages over conventional technology. For example: microstructured devices have up to three orders of magnitude higher surface to volume ratio compared to conventional apparatuses. This results in intensified heat transfer. Microreactors are an excellent solution for extremely fast and highly exothermic or endothermic reactions. These reactions can be much better controlled in a microreactor and the possibility of hot spot for homogenous or heterogeneous reaction will be minimized. In conventional reactors strong temperature profiles could influence the product spectrum, and in some case even the catalyst can be irreversibly damaged. Micro process technology therefore can be used to perform hard to control reactions, which otherwise cannot be performed in a conventional reactor. Due to very high surface to volume ratio, the mass transfer limited processes can also take advantage of micro process technology. In micromixers the mixing velocity is an order of magnitude higher then in conventional mixers, which results in smaller mixing sections, a few millimeters or even less. Another advantage of micro devices is the option to control and adjust the process parameters much better. This leads not only to a better yield, but also to a higher level of safety. Additionally costs for downstream processing can be reduced significantly: for example by a solvent free production, production of reduced waste material during start up or shut down, change of product or potential production interference because of the small hold ups in continuous operating microreaction plants etc. Using micro process technology, the development of products or continuous processes, e.g. transfer from batch to continuous production could be accelerated significantly. Additionally, new synthesis routes are possible, which can not be realized in a conventional apparatuses in a cost effective manner, such as highly exothermic reactions. For this kind of applications micro process technology is most suitable. Modular micro process systems consist of different types of modules, including mixers, heat exchangers, reactors, sensors, actuators and fluidic and electrical interfaces. All these modules are fully or partially equipped with microstructures. These modules cover essential unit operations within the reaction technology. Additionally the systems are equipped for measuring pressure, temperature and flow rates. Also analytic modules are available, which allow us to determine the quality of the product e.g. using NIR- or UV/VIS-spectroscopy. New developed modules (residence time, photo chemistry reactor, separation etc.), sensors ( e.g. pH, coriolis flow meter), actors (temperature control unit, valves) and module materials will be shown in the presentation. With minimal effort, a whole lab or pilot plant can be installed with the modular microreaction systems. In conjunction with process control system and peripheral equipments, these microreaction systems are powerful development and production tools, which allow innovations in all areas of the chemical industry. A micro process system as a flexible pilot plant has been demonstrated for small production. Also, if the holdup of the unit is small, production rates up to several tons is possible. In addition to liquid, gas-liquid and gas phase reactions, microreaction technology can also be used to produce micro- and nanoparticles. For example, modules, which were developed for precipitation reactions, can be used to produce pigments and catalysts. The advantages of suspension handling and the production of solid particles with specified properties lead to process innovations, which have already been installed in small production plants. Additionally some microreactors, allow the handling of slurries. The scale-up from lab to bulk production can be achieved by parallel connection of microreaction technology plants or by scale-up of the modules by multiplying the microstructures reaching production rates up several thousand tons per year. This indicates that microreaction technology could be a viable alternative to conventional production units. For successful process development, a combined knowledge of micro process technology concepts along with conventional plant design process, reaction engineering and process chemistry is essential. This holistic approach is the key to innovative, micro process technology-based solutions for efficient processes and high-performance plants. This will be also shown in the presentation for selected applications.