(8f) Particle Loading in a Catalyst-Trap Microreactor for Fine Chemical Synthesis: Simulation Vs. Experimentation

The ?catalyst-trap? microreactor a novel design for multiphase microscale reactions was recently reported by S. McGovern [1] et al. The ?catalyst trap? was designed to individually capture particles in order to enhance catalytic efficiency, eliminate unwanted by-products and improve the heat transfer of reactions. The reductive hydrogenation of 3-nitrotoluene with 5 wt% Pd/C in this microreactor was investigated, which gave us a 100% yield in a short reaction time. However the low catalyst loading (~20% of full capacity) present in the catalyst trap for the reductive hydrogenation reaction is potentially insufficient for more sensitive reactions with lower activities. The loading procedure was explored using both simulation and experimentation to ultimately improve the implementation of the catalyst trap microreactor in organic chemical synthesis and production. Simulations based on a random-walk model and loading experiments were specifically conducted to understand the filling mechanism. After studying the loading procedure, 98% of the designed loading was successfully achieved. We found the physical catalyst loading procedure was most consistent with simulation of an incoming particle flow employing a parabolic particle flow distribution. Through this work, catalytic area and catalytic efficiency have been significantly increased, and the synthetic capability of the catalyst trap microreactor enhanced as a result.