Continuous flow (micro-)reactors for heterogeneously catalyzed reactions: Main design and modelling issues

Synthetic Chemistry in Flow: From Photolysis & Homogeneous Photocatalysis to Heterogeneous Photocatalysis

Photocatalytic synthesis of value-added chemicals has gained increasing attention in recent years owing to its versatility in driving many important reactions under ambient conditions. Selective hydrogenation, oxidation, coupling, and halogenation with a high conversion of the reactants have been realized using designed photocatalysts in batch reactors with small volumes at a laboratory scale; however, scaling-up remains a critical challenge due to inefficient utilization of incident light and active sites of the photocatalysts, resulting in poor catalytic performance that hinders its practical applications. Flow systems are considered one of the solutions for practical applications of light-driven reactions and have experienced great success in photolytic and homogeneous photocatalysis, yet their applications in heterogeneous photocatalysis are still under development. In this perspective, we have summarized recent progress in photolytic and photocatalytic synthetic chemistry performed in flow systems from the view of reactor design with a special focus on heterogeneous photocatalysis. The advantages and limitations of different flow systems, as well as some practical considerations of design strategies are discussed.

Modeling of a Two-Bed Reactor for Low-Temperature Removal of Nitrogen Oxides in Nitric Acid Production

In this study, the modeling of the low-temperature catalytic abatement of NOX and N2O from tail gases in a weak nitric acid plant utilizing a single-pressure 0.716 MPa system was performed. A one-reactor concept assumes that in the first bed, NOX is reduced by ammonia on a commercial vanadia–alumina catalyst, and in the second bed, N2O is decomposed on a proprietary nickel–cobalt catalyst. The kinetics of N2O decomposition on a Cs/Ni0.1Co2.9O4 catalyst was experimentally studied in an isothermal flow reactor. The reaction rate constants were determined by varying the residence time and temperature; these data formed the basis for modeling kinetics and heat and mass transport in an adiabatic reactor in which the low-temperature mitigation of nitrogen oxides occurred. Taking into account the given spatial limitations inside the reactor and the allowable temperatures, the layer heights were evaluated to ensure a residual NOX and N2O content of less than 50 ppm. Catalyst loading using layers in a commercial reactor was estimated for the tail-gas flow rates of 46,040–58,670 m3/h. Simulations showed that the optimum inlet temperature was 260 °C; in this case, the NOX and N2O conversion targets were achieved in the range of 46,040–58,670 m3/h while adhering to catalyst bed height and outlet temperature limitations.

Additive manufacturing of microstructured reactors for organometallic catalytic reactions

The use of Additive Manufacturing for the fabrication of chemical reactors for flow chemistry is a promising field as it can lead to several improvements over more standard equipment. In this work, two different reactors were fabricated and compared: a Honeycomb monolith reactor with straight channels and a Periodic Open Cell Structure reactor. The Honeycomb monolith reactor was used as an example of a standard reactor (not necessarily additive manufactured) while the Periodic Open Cell Structure is a promising new type of reactor, which improves some key features, such as contact surface area and porosity. The two reactors were manufactured by Stereolithography technology with a high temperature resin and their internal surfaces were chemically activated by the grafting of palladium. For the surface activation, a two-step procedure was developed, firstly using NaOH and in a second step an aqueous solution of Na₂PdCl₄. After activation, a heterogeneous catalytic reaction was used to characterize the performance of the two fabricated reactors. The chosen reaction was the Suzuki-Miyaura reaction, which is commonly used in the pharmaceutical industry. The experimental results showed that, for equal contact surface area, the new designed reactor had better performance compared to the standard geometry.

Design of a Microfluidic Photocatalytic Reactor for Removal of Volatile Organic Components: Process Simulation and Techno-Economic Assessment

This study reports on a gas-phase photocatalytic microreactor (MR) employed for the degradation of 2-propanol in indoor air. A process flow diagram was developed and simulated in Aspen Hysys V10, and a techno-economic assessment was carried out based on the simulated results. An economic evaluation was carried out using a fixed and demand-dependent variable cost model. Decreasing the mass flow rate or the initial concentration of the 2-propanol in indoor air and increasing the diameter or length of the MR resulted in a better air remediation efficacy. Sensitivity analysis for the economics of the manufactured MR showed that the optimal plant production volume is 10,000 units per year. At this volume, the total manufacturing cost was 2.8 M$/y with a production cost of $ 127 per unit and a levelized cost of a MR (LCOM) of about $ 280 per unit. These findings herein can help bolster research into both technical and economic aspects of MR production for the photocatalytic remediation of air. The resulting design could be applied in air conditioner units and other home ventilation units for the removal of harmful volatile organic compounds in the air.

Liquid-phase catalytic hydrodechlorination of chlorinated organic compounds in a continuous flow micro-packed bed reactor over a Pd/AC catalyst

A continuous flow system based on a micro-packed bed reactor was developed for hydrodechlorination, and the hydrogenation of chlorobenzene was selected as the model reaction. With the optimal reaction conditions, a conversion and selectivity of 100% were obtained.

Degradation of anthraquinone dye reactive blue 19 using persulfate activated with Fe/Mn modified biochar: Radical/non-radical mechanisms and fixed-bed reactor study

In this study, a heterogeneous activator was prepared via the Fe/Mn modification of sludge-derived biochar (Fe/MnBC) to achieve high-efficiency activation of persulfate (PS) for reactive blue 19 (RB19) degradation. The morphologies and chemical states of Fe/MnBC were examined by various characterizations. A comprehensive assessment was conducted to reveal the effects of biochar preparation conditions and system reaction conditions. According to the results of scavenger quenching experiments and electron paramagnetic resonance (EPR) testing, the mechanisms of Fe/MnBC combined PS system on RB19 degradation were proposed, including radical and non-radical mechanisms. The formation and involvement of sulfate radical (SO₄^·-), hydroxyl radical (OH^·), and singlet oxygen (¹O₂) were proved in this system, and Fe(IV)/Mn(VII) was also speculated to participate in the non-radical degradation process. These findings give a new insight into the mechanisms of PS activated by metal-biochar composite. Besides, fixed-bed reactor (FBR) experiments indicated that the Fe/MnBC has considerable PS activation potential for dyes removal. The degradation process was further modeled by the central composite design (CCD-RSM) and artificial neural networks (ANN) methods. The statistical metrics and prediction indicated that the prediction results of ANN model were better than CCD-RSM model, and the ANN model could perfectly predict the reaction process of Fe/MnBC FBR for engineering applications.

Panchromatic Ternary Polymer Dots Involving Sub-Picosecond Energy and Charge Transfer for Efficient and Stable Photocatalytic Hydrogen Evolution

Panchromatic ternary polymer dots (Pdots) consisting of two conjugated polymers (PFBT and PFODTBT) based on fluorene and benzothiadiazole groups, and one small molecular acceptor (ITIC) have been prepared and assessed for photocatalytic hydrogen production with the assistance of a Pt cocatalyst. Femtosecond transient absorption spectroscopic studies of the ternary Pdots have revealed both energy and charge transfer processes that occur on the time scale of sub-picosecond between the different components. They result in photogenerated electrons being located mainly at ITIC, which acts as both electron and energy acceptor. Results from cryo-transmission electron microscopy suggest that ITIC forms crystalline phases in the ternary Pdots, facilitating electron transfer from ITIC to the Pt cocatalyst and promoting the final photocatalytic reaction yield. Enhanced light absorption, efficient charge separation, and the ideal morphology of the ternary Pdots have rendered an external quantum efficiency up to 7% at 600 nm. Moreover, the system has shown a high stability over 120 h without obvious degradation of the photocatalysts.

1,3-Dipolar Cycloaddition Reactions of Nitrile Oxides under "Non-Conventional" Conditions: Green Solvents, Irradiation, and Continuous Flow

The 1,3-dipolar cycloaddition reactions (DCs) of nitrile oxides (NOs) to alkenes and alkynes are useful methods for the synthesis of 2-isoxazolines and isoxazoles respectively, which are important classes of heterocyclic compounds in organic and medicinal chemistry. Most of these reactions are carried out in organic solvents and under thermal activation. Nevertheless the use of supercritical carbon dioxide (scCO₂ ) and ionic liquids (Ils) as alternative solvents and the application of microwave (MW) and ultrasound (US) as alternative activation procedures have evident advantages from the "Green Chemistry" point of view. The critical discussion on the applications of these "unconventional" activation methods and reaction conditions in the 1,3-DCs of NOs is the objective of the present Review.

Transesterification of Sunflower Oil over Waste Chicken Eggshell-Based Catalyst in a Microreactor: An Optimization Study

The statistical experimental design (DoE) and optimization (Response Surface Methodology combined with Box-Behnken design) of sunflower oil transesterification catalyzed by waste chicken eggshell-based catalyst were conducted in a custom-made microreactor at 60 °C. The catalyst was synthesized by the hydration-dehydration method and subsequent calcination at 600 °C. Comprehensive characterization of the obtained catalyst was conducted using: X-ray powder diffractometry (XRD), X-ray fluorescence (XRF), Fourier-transform infrared (FT-IR) spectroscopy, scanning electron microscopy (SEM), N₂ physisorption, and Hg-porosimetry. Structural, morphological, and textural results showed that the obtained catalyst exhibited high porosity and regular dispersity of plate-like CaO as an active species. The obtained optimal residence time, catalyst concentration, and methanol/oil volume ratio for the continuous reaction in microreactor were 10 min, 0.1 g g^-1, and 3:1, respectively. The analysis of variance (ANOVA) showed that the obtained reduced quadratic model was adequate for experimental results fitting. The reaction in the microreactor was significantly intensified compared to a conventional batch reactor, as seen through the fatty acid methyl esters (FAMEs) content after 10 min, which was 51.2% and 18.6%, respectively.

Continuous Flow Upgrading of Selected C2-C6 Platform Chemicals Derived from Biomass

The ever increasing industrial production of commodity and specialty chemicals inexorably depletes the finite primary fossil resources available on Earth. The forecast of population growth over the next 3 decades is a very strong incentive for the identification of alternative primary resources other than petro-based ones. In contrast with fossil resources, renewable biomass is a virtually inexhaustible reservoir of chemical building blocks. Shifting the current industrial paradigm from almost exclusively petro-based resources to alternative bio-based raw materials requires more than vibrant political messages; it requires a profound revision of the concepts and technologies on which industrial chemical processes rely. Only a small fraction of molecules extracted from biomass bears significant chemical and commercial potentials to be considered as ubiquitous chemical platforms upon which a new, bio-based industry can thrive. Owing to its inherent assets in terms of unique process experience, scalability, and reduced environmental footprint, flow chemistry arguably has a major role to play in this context. This review covers a selection of C₂ to C₆ bio-based chemical platforms with existing commercial markets including polyols (ethylene glycol, 1,2-propanediol, 1,3-propanediol, glycerol, 1,4-butanediol, xylitol, and sorbitol), furanoids (furfural and 5-hydroxymethylfurfural) and carboxylic acids (lactic acid, succinic acid, fumaric acid, malic acid, itaconic acid, and levulinic acid). The aim of this review is to illustrate the various aspects of upgrading bio-based platform molecules toward commodity or specialty chemicals using new process concepts that fall under the umbrella of continuous flow technology and that could change the future perspectives of biorefineries.

Enzyme Immobilization in Wall-Coated Flow Microreactors

Flow microreactors are emergent engineering tools for the development of continuous biocatalytic transformations. Exploiting enzymes in continuous mode requires their retention for multiple rounds of conversions. To achieve this goal, immobilizing the enzymes on microchannel walls is a promising approach. However, protein immobilization within closed structures is difficult. Here, we describe a methodology based on the confluent design of enzyme and microreactor; fusion to the silica-binding module Z_basic2 is used to engineer enzymes for high-affinity-oriented attachment to the plain wall surface of glass microchannels. As a practical case, the methodology is described using a sucrose phosphorylase; the assayed reaction is synthesis of α-D-glucose 1-phosphate (αGlc 1-P) from sucrose and phosphate using the immobilized enzyme microreactor. Procedures of enzyme immobilization, reactor characterization, and operation are described. The methodology is applicable for any other enzymes fused to Z_basic2 and silica (glass)-based microfluidic reactors.

Metal organic frameworks as solid catalysts for liquid-phase continuous flow reactions

This Feature Article describes the recent developments in the use of MOFs as catalysts under continuous flow conditions illustrating that these materials can meet the required stability.

Leloir Glycosyltransferases in Applied Biocatalysis: A Multidisciplinary Approach

Enzymes are nature’s catalyst of choice for the highly selective and efficient coupling of carbohydrates. Enzymatic sugar coupling is a competitive technology for industrial glycosylation reactions, since chemical synthetic routes require extensive use of laborious protection group manipulations and often lack regio- and stereoselectivity. The application of Leloir glycosyltransferases has received considerable attention in recent years and offers excellent control over the reactivity and selectivity of glycosylation reactions with unprotected carbohydrates, paving the way for previously inaccessible synthetic routes. The development of nucleotide recycling cascades has allowed for the efficient production and reuse of nucleotide sugar donors in robust one-pot multi-enzyme glycosylation cascades. In this way, large glycans and glycoconjugates with complex stereochemistry can be constructed. With recent advances, LeLoir glycosyltransferases are close to being applied industrially in multi-enzyme, programmable cascade glycosylations.

Compact Steam-Methane Reforming for the Production of Hydrogen in Continuous Flow Microreactor Systems

The implementation of fuel cell deployment requires efficient conversion of fuels into hydrogen in a distributed energy system. Fortunately, continuous flow and microreactor technology provide unique opportunities for the portable production of hydrogen. This study focuses on determining the operation space for a thermally integrated methane reforming system, thereby providing a theoretical basis for the design and optimization of such systems. The steam-methane reforming over rhodium coupled with methane combustion over platinum in a thermally integrated microchannel reactor arranged with rectangular-shaped protuberances was studied numerically in order to improve its operability and stability. Computational fluid dynamic simulations were carried out with detailed reaction mechanisms to identify conditions for the maximum hydrogen yield and the highest output power. Various operating lines were presented, and various performance metrics were evaluated accordingly. The results indicated that the efficient production of hydrogen is made possible through improving transport performance for highly active catalysts. The flow disturbance elements designed for the reactor are of great benefit to intensification of the reforming process. There exists a trade-off between fuel utilization and output power. Autothermal operation advantages from improved transport performance in small physical dimensions were demonstrated for the system, but careful thermal management is always necessary to ensure its efficient and stable operation. The thermal conductivity of the wall separating the exothermic and endothermic reactions plays a significant role in determining the performance of the system. Highly active catalysts are required to intensify the overall reforming process and to achieve efficient thermal management. Adjustment of fluid velocities can serve as a convenient means to achieve efficient operation of the system.

Catalytic Hydrodechlorination of Chlorophenols in a Continuous Flow Pd/CNT-Ni Foam Micro Reactor Using Formic Acid as a Hydrogen Source

Catalytic hydrodechlorination (HDC) has been considered as a promising method for the treatment of wastewater containing chlorinated organic pollutants. A continuous flow Pd/carbon nanotube (CNT)-Ni foam micro reactor system was first developed for the rapid and highly efficient HDC with formic acid (FA) as a hydrogen source. This micro reactor system, exhibiting a higher catalytic activity of HDC than the conventional packed bed reactor, reduced the residence time and formic acid consumption significantly. The desired outcomes (dichlorination >99.9%, 4-chlorophenol outlet concentration <0.1 mg/L) can be obtained under a very low FA/substrate molar ratio (5:1) and short reaction cycle (3 min). Field emission scanning electron microcopy (FESEM) and deactivation experiment results indicated that the accumulation of phenol (the main product during the HDC of chlorophenols) on the Pd catalyst surface can be the main factor for the long-term deactivation of the Pd/CNT-Ni foam micro reactor. The catalytic activity deactivation of the micro reactor could be almost completely regenerated by the efficient removal of the absorbed phenol from the Pd catalyst surface.

Demystifying the Flow: Biocatalytic Reaction Intensification in Microstructured Enzyme Reactors

Continuous (flow) reactors have drawn a wave of renewed interest in biocatalysis. Many studies find that the flow reactor offers enhanced conversion efficiency. What the reported reaction intensification actually consists in, however, often remains obscure. Here, a canonical microreactor design for heterogeneously catalyzed continuous biotransformations, featuring flow microchannels that contain the enzyme immobilized on their wall surface are examined. Glycosylations by sucrose phosphorylase are used to assess the potential for reaction intensification due to microscale effects. Key variables are identified, and their corresponding relationship equations, to describe, and optimize, the interplay between reaction characteristics, microchannel geometry and reactor operation. The maximum space-time-yield (STY_max) scales directly with the enzyme activity immobilized on the available wall surface. Timescale analysis, comparing the characteristic times of reaction (τ_reac ) and diffusion (τ_diff ) to the mean residence time (τ_res ), reveals operational conditions for optimum reactor output. Theoretical insight into determinants of microreactor performance is applied to biocatalytic syntheses of α-d-glucose 1-phosphate and α-glucosyl glycerol. Process boundaries for enzyme showing, respectively, high (80 U mg^-1 ) and low (4 U mg^-1 ) specific activities are thus established and options for process design revealed. Opportunities, and limitations, of the application of principles of microscale flow chemistry to biocatalytic transformations are made evident.