Microstructured Reactors for Multiphase Reactions: State of the Art

Micromixing Intensification within a Combination of T-Type Micromixer and Micropacked Bed

The combination of microstructural units is an effective strategy to improve the micromixing of liquid phase systems, especially viscous systems. However, how the microstructural combination influences micromixing is still not systematically investigated. In this work, the Villermaux/Dushman reaction is used to study the micromixing performance of the viscous system of the glycerol-water in the combination of a T-type micromixer and a micropacked bed. Micromixing performances under various structural parameters and fluid characteristics are determined and summarized, and the micromixing laws are revealed by dimensionless analysis considering the specific spatial characteristics and temporal sequence in the combined microstructures. It achieves good agreement with experimental results and enables guidance for the design and scaling-up of the combined T-type micromixer and micropacked bed towards micromixing intensification in viscous reaction systems.

Production of performic acid through a capillary microreactor by heterogeneous catalyst

Microreactors are small in size with significant heat and mass transfer. Performic acid (PFA) is an important organic compound. It has broad applications in food, oil and chemical industries because of its oxidizing properties. In the present work PFA is produced in a continuous flow Teflon spiral capillary microreactor. The PFA is produced with and without a heterogeneous catalyst. The formic acid (FA) and hydrogen peroxide (HP) are the reactants to produce the PFA. It is a reversible reaction. The aim of the present work to monitor the consequence of hydrogen peroxide concentration, temperature and heterogeneous catalyst (Amberlite) for conversion of the FA. The experimental results showed that the formation of the PFA is effected with increase in hydrogen peroxide concentration, percentage of catalyst and temperature. The PFA formed within short residence time by the use of solid catalyst. The heterogeneous catalysts are better in decreasing corrosion and segregation of the catalyst compared to homogeneous catalysts. The best conditions for the PFA synthesis reaction were noted that 10 min residence time, 30 w/v% of HP, 6 wt% of catalyst concentration based on formic acid and 30 °C. Hence, the maximum concentration of the PFA was recorded 2.8 mol/L (XFA = 39.4%)

Recent Progress and Prospects in Catalytic Water Treatment

Presently, conventional technologies in water treatment are not efficient enough to completely mineralize refractory water contaminants. In this context, the implementation of catalytic processes could be an alternative. Despite the advantages provided in terms of kinetics of transformation, selectivity, and energy saving, numerous attempts have not yet led to implementation at an industrial scale. This review examines investigations at different scales for which controversies and limitations must be solved to bridge the gap between fundamentals and practical developments. Particular attention has been paid to the development of solar-driven catalytic technologies and some other emerging processes, such as microwave assisted catalysis, plasma-catalytic processes, or biocatalytic remediation, taking into account their specific advantages and the drawbacks. Challenges for which a better understanding related to the complexity of the systems and the coexistence of various solid-liquid-gas interfaces have been identified.

Gas-liquid mass transfer intensification for bubble generation and breakup in micronozzles

The local gas-liquid mass transfer was characterized during bubble generation in T-contactors and in an adjacent micronozzle. A colorimetric technique with the oxygen sensitive dye resazurin was investigated to visualize gas-liquid mass transfer during slug flow, bubble deformation, as well as laminar and turbulent bubble breakup in the wake of a micronozzle. Two optimized nozzle geometries from previous studies were evaluated concerning volumetric mass transfer coefficients for low pressure loss, narrow residence time distribution, or high dispersion rates. Highest values in kla up to 60 s−1 were found for turbulent bubble breakup and an optimized micronozzle design in respect to pressure drop and dispersion rate. The achieved mass transfer coefficients were correlated with the energy dissipation rate within the micronozzles and with the inverse Kolmogorov time scale in vortex dissipation in good agreement for laminar and turbulent breakup regimes.

Graphical abstract

An intensified chlorination process of 4-nitroaniline in a liquid–liquid microflow system

A strategy of dissolving chlorine gas in 1,2-dichloroethane for a liquid–liquid two-phase chlorination reaction was proposed to resolve the problems of low efficiency, strong corrosivity, and poor controllability of gas–liquid chlorination.

MONOPHASIC REACTION WITH A PACKED BED MICROREACTOR: CHARACTERIZATION OF MASS TRANSFER AND REACTION

In this paper, the monophasic catalytic reaction in the microreactor is studied. Several factors that may affect the catalytic reaction are discussed, including the pressure drop, the size of catalyst particles, and the channel structure. Finally, some important conclusions can be reached. The change of pressure drop has an effect on the reaction. For example, the C3H6 conversion rate is 62.88% when the pressure drop is 8[Formula: see text]atm, and the C3H6 conversion rate is 61.78% when the pressure drop is 11[Formula: see text]atm. The effect of the change particle radius is not obvious on the reaction. Enhancing the mixing of substances before entering the reaction domain is helpful to the catalytic reaction. There are different substances concentration in catalyst particles at different positions in microreactors. But from the surface to the inside of catalyst particles, the substances concentration has a clear change rule.

Confined multiphase swirled flows in chemical engineering

Exploration of confined swirled flows in the former USSR and present-day Russia has a long history and is presented by numerous publications, mostly written in Russian. The obtained results have been put to practical use in different areas of chemical, energy, and processing industries. In view of the process intensification concept, such characteristics of confined swirled flows may be considered unique: high centrifugal gravity, elongation of trajectories, the presence of internal separation zones, energy separation phenomena, and efficient mass/heat transfer in the absence of any moving parts. For instance, high gravity provides an excellent opportunity for multiphase flow stabilization, preventing the appearance of nonuniformities and stability loss, while enhancement of various driving forces acting on the reaction medium takes place. This review is devoted to outlining the main research trends and to discuss the most essential practical implementations in the subject matter done up until now. It is not foreseen to embrace the whole area of swirled flow investigations in the world, but only covers most of the significant ideas and applications contributed in by former Soviet and Russian scientists and engineers. Shortcomings and difficulties of using swirled flows are also briefly discussed.

Mass transfer in falling film microreactors: measurement techniques and effect of operational parameters

Falling film microreactors have contributed to the pursuit of process intensification strategies and have, over the years, been recognized for their potential in performing demanding reactions. In the last few decades, modifications in the measurement techniques and operational parameters of these microstructured devices have been the focus of many research studies with a common target on process improvement. In this work, we present a review dedicated to falling film microreactors, focusing on the recent advances in their design and operation, with particular emphasis on mass transfer enhancement. Analysis of the recent techniques for the measurement of mass transfer as well as the operational parameters used and their effect on the target objective, particularly in the liquid phase (being the limiting phase reactant), are included in the review. The relationship between the hydrodynamics of falling thin liquid films and the microreactor design, the discrepancies between measured and model results, the major challenges, and the future outlook for these promising microreactors are also presented.

Enabling tools for continuous-flow biphasic liquid–liquid reaction

This minireview offers an up-to-date overview of enabling tools for biphasic liquid–liquid reactions in flow.

Tailoring the multiphase flow pattern of gas and liquid through micro-packed bed of pillars

We describe the co-current flow pattern of gas and liquid through micro-fabricated beds of solid and pillars under variable (i) capillary number, (ii) contact angle or wettability and (iii) pillar arrangement, i.e. modifying the distance between pillars or their size and comparing regular with more chaotic systems.

Lipase-catalyzed solvent-free synthesis of erythorbyl laurate in a gas-solid-liquid multiphase system

Erythorbyl laurate is a potential food additive as a multi-functional emulsifier having antioxidant and antimicrobial activities. In this study, a gas-solid-liquid multiphase system (GSL-MPS) was established to enhance the production yield of erythorbyl laurate in a lipase-catalyzed solvent-free synthesis. The significant reaction variables were optimized as follows: substrate molar ratio of 2:1 (lauric acid:erythorbic acid) and enzyme concentration of 120 mg/mL (840 PLU/mL). Under these conditions, the maximum production yield in GSL-MPS was 13.974 mg/mL, which is 8.60- and 4.26-fold higher than the yields obtained in an organic solvent monophase system (OS-MPS) and a solid-liquid biphase system (SL-BPS), respectively. Moreover, the operational stability of the immobilized lipase was significantly improved in GSL-MPS compared with OS-MPS. These results indicate that GSL-MPS can be an enzymatic reaction system facilitating efficient production of ester compounds as a means of increasing production yields and the reusability of the immobilized lipase.

Hydrodynamic shrinkage of liquid CO2 Taylor drops in a straight microchannel

Hydrodynamic shrinkage of liquid CO2 drops in water under a Taylor flow regime is studied using a straight microchannel (length/width ~100). A general form of a mathematical model of the solvent-side mass transfer coefficient (k s) is developed first. Based on formulations of the surface area (A) and the volume (V) of a general Taylor drop in a rectangular microchannel, a specific form of k s is derived. Drop length and speed are experimentally measured at three specified positions of the straight channel, namely, immediately after drop generation (position 1), the midpoint of the channel (position 2) and the end of the channel (position 3). The reductions of drop length (L x , x  =  1, 2, 3) from position 1 to 2 and down to 3 are used to quantify the drop shrinkage. Using the specific model, k s is calculated mainly based on L x and drop flowing time (t). Results show that smaller CO2 drops produced by lower flow rate ratios ([Formula: see text]) are generally characterized by higher (nearly three times) k s and Sherwood numbers than those produced by higher [Formula: see text], which is essentially attributed to the larger effective portion of the smaller drop contributing in the mass transfer under same levels of the flowing time and the surface-to-volume ratio (~104 m-1) of all drops. Based on calculated pressure drops of the segmented flow in microchannel, the Peng-Robinson equation of state and initial pressures of drops at the T-junction in experiments, overall pressure drop (ΔP t) in the straight channel as well as the resulted drop volume change are quantified. ΔP t from position 1-3 is by average 3.175 kPa with a ~1.6% standard error, which only leads to relative drop volume changes of 0.3‰ to 0.52‰.

Process intensification

Process intensification (PI) is a rapidly growing field of research and industrial development that has already created many innovations in chemical process industry. PI is directed toward substantially smaller, cleaner, more energy-efficient technology. Furthermore, PI aims at safer and sustainable technological developments. Its tools are reduction of the number of devices (integration of several functionalities in one apparatus), improving heat and mass transfer by advanced mixing technologies and shorter diffusion pathways, miniaturization, novel energy techniques, new separation approaches, integrated optimization and control strategies. This review discusses many of the recent developments in PI. Starting from fundamental definitions, microfluidic technology, mixing, modern distillation techniques, membrane separation, continuous chromatography, and application of gravitational, electric, and magnetic fields will be described.

Ultrasound assisted synthesis of performic acid in a continuous flow microstructured reactor

The present work establishes in depth study of ultrasound assisted preparation of performic acid (PFA) in a continuous flow microstructured reactor. The influence of various parameters viz. formic acid: hydrogen peroxide molar ratio, flow rate, temperature and catalyst loading on the PFA formation were studied in a continuous flow microstructured reactor. In a continuous microstructured reactor in the presence of ultrasonic irradiation, the formation of PFA was found to be dependent on the molar ratio of formic acid: hydrogen peroxide, flow rate of reactants, temperature and catalyst loading (Amberlite IR-120H). The optimized parameter values are 1:1M ratio, 50mL/h, 40°C and 471mg/cm³ respectively. Further, the performance of Amberlite IR-120H catalyst was evaluated for three successive cycles in continuous microstructured reactor. The performance of catalyst was found to be decreased with the usage of the catalyst and is attributed to neutralization of the sulfonic acid groups, catalyst shrinkage, or loss in pore sites. The experimental results revealed that, for an ultrasound assisted synthesis of PFA in continuous microstructured reactor the observed reaction time was even less than 10min. The observed intensification in the PFA synthesis process can be attributed to the intense collapse of the cavities formed at low temperature during ultrasonic irradiations, which further improved the heat and mass transfer rates with the formation of H₂O₂ during the reaction. The combined use of ultrasound and a continuous flow microstructured reactor has proved beneficial process of performic acid synthesis.

The Hitchhiker's Guide to Flow Chemistry ∥

Flow chemistry involves the use of channels or tubing to conduct a reaction in a continuous stream rather than in a flask. Flow equipment provides chemists with unique control over reaction parameters enhancing reactivity or in some cases enabling new reactions. This relatively young technology has received a remarkable amount of attention in the past decade with many reports on what can be done in flow. Until recently, however, the question, "Should we do this in flow?" has merely been an afterthought. This review introduces readers to the basic principles and fundamentals of flow chemistry and critically discusses recent flow chemistry accounts.

Continuous-flow processes for the catalytic partial hydrogenation reaction of alkynes

The catalytic partial hydrogenation of substituted alkynes to alkenes is a process of high importance in the manufacture of several market chemicals. The present paper shortly reviews the heterogeneous catalytic systems engineered for this reaction under continuous flow and in the liquid phase. The main contributions appeared in the literature from 1997 up to August 2016 are discussed in terms of reactor design. A comparison with batch and industrial processes is provided whenever possible.

Micromixing enhanced synthesis of HRPIBs catalyzed by EADC/bis(2-chloroethyl)ether complex

Better mixing could produce more active centers to accelerate the polymerization by promoting the consumption of carbonium ions.

Local and overall heat transfer of exothermic reactions in microreactor systems

Heat transfer performance of plate-type metallic microreactors.