Influence of mixing performance on polymerization of acrylamide in capillary microreactors

Continuous Synthesis of Spherical Polyelectrolyte Brushes by Photo-Emulsion Polymerization in a Microreactor

Nanosized spherical polyelectrolyte brushes (SPBs) are ideal candidates for the preparation of nanometal catalysts, protein separation, and medical diagnostics. Until now, SPBs have been synthesized by photo-emulsion polymerization in a batch reactor, which remains challenging to scale up. This paper reports a successful continuous preparation of SPBs by photo-emulsion polymerization in a self-made microreactor. The effects of residence time, monomer concentration, and feed ratios on the conversion of monomers and SPB structures are systematically investigated by dynamic lighting scattering and transmission electron microscopy. Poly(acrylic acid) (PAA) SPBs obtained in a microreactor exhibiting a narrow size distribution with a short reaction time are very effective in inhibiting the calcium carbonate scale and are comparable to those produced in a batch reactor. This work confirms the feasibility of continuous preparation and scaled-up production of SPBs.

Anionic polymerizations in a microreactor

Anionic polymerizations in a microreactor enable fast mixing, high-level control, and scale-up synthesis of polymers.

CFD analysis of asymmetric mixing at different inlet configurations of a split-and-recombine micro mixer

In the scope of the ENPRO II initiative (Energy Efficiency and Process Intensification for the Chemical Industry), a major challenge of process intensification of polymer synthesis in continuous systems is fouling. Pre-mixing is a key aspect to prevent fouling and is achieved through milli and micro structured devices (Bayer et al. 1). While equal volume flow ratios are well investigated in milli and micro systems, asymmetric mixing tasks have received less attention. This paper investigates the dependency of mixing phenomena on different flow rate ratios and modified inlet geometries. A split-and-recombine (SAR) mixer is modified by means of an injection capillary to facilitate the asymmetric mixing task. Asymmetric volume flows of ratios between 1:15 and 1:60 are investigated; the velocity ratios range from 0.5 to 2. The setup is simulated with the Computational Fluid Dynamics (CFD) tool ANSYS®;Fluent. The species equation is solved directly without the use of micro mixing models. The simulation is validated by means of a concentration field in a mixing Tee using Laser-Induced Fluorescence (LIF) with a Confocal Laser Scanning Microscope (CLSM). The three dimensional flow structures and the mixing quality are analyzed as a measure for micro mixing. The calculated concentration fields show good agreement with the experimental results and reveal the secondary flow structures and chaotic advection within the channel. The injection of the small feed stream is found to be very efficient when drawn into the secondary structures, increasing the potential of diffusive mixing. CFD simulations help to understand and locate such structures and improve the mixing performance.

Activation of homogenous polyolefin catalysis with a machine-assisted reactor laboratory-in-a-box (μAIR-LAB)

Catalysis discovery is typically limited to specialized labs – this work demonstrates an Artificially Intelligent Microreactor Lab in a Box applied to investigate the chemistry of different co-catalysts for zirconocene-catalyzed olefin polymerization.

Enabling technologies in polymer synthesis: accessing a new design space for advanced polymer materials

This review discusses how developments in laboratory technologies can push the boundaries of what is achievable using existing polymer synthesis techniques.

Numbering-up of capillary microreactors for homogeneous processes and its application in free radical polymerization

Different numbered-up capillary microreactor systems were assembled with commercially available parts for homogeneous processes with significant variation of fluid properties (e.g., free radical polymerization), and statistical analysis was performed to reveal its flow distribution performance.

Highly efficient conversion of CO2 to cyclic carbonates with a binary catalyst system in a microreactor: intensification of “electrophile–nucleophile” synergistic effect

An intensification of the “electrophile–nucleophile” synergistic effect was achieved in a microreactor for the coupling reaction of CO₂ and epoxides mediated by the binary Al complex/ternary ammonium salt catalyst system. The microreactor technology is proven to be a powerful tool for the preparation of cyclic carbonates with an improved reaction rate and a wide substrate scope.

An intensification of the “electrophile–nucleophile” synergistic effect was achieved in a microreactor for the coupling reaction of CO₂ and epoxides mediated by the binary Al complex/ternary ammonium salt catalyst system.