1
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Gnädinger U, Poier D, Trombini C, Dabros M, Marti R. Development of Lab-Scale Continuous Stirred-Tank Reactor as Flow Process Tool for Oxidation Reactions Using Molecular Oxygen. Org Process Res Dev 2024; 28:1860-1868. [PMID: 38783850 PMCID: PMC11110044 DOI: 10.1021/acs.oprd.3c00424] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/03/2023] [Revised: 03/30/2024] [Accepted: 04/03/2024] [Indexed: 05/25/2024]
Abstract
The use of sustainable oxidants is of great interest to the chemical industry, considering the importance of oxidation reactions for the manufacturing of chemicals and society's growing awareness of its environmental impact. Molecular oxygen (O2), with an almost optimal atom efficiency in oxidation reactions, presents one of the most attractive alternatives to common reagents that are not only toxic in most cases but produce stoichiometric amounts of waste that must be treated. However, fire and explosion safety concerns, especially when used in combination with organic solvents, restrict its easy use. Here, we use state-of-the-art 3D printing and experimental feedback to develop a miniature continuous stirred-tank reactor (mini-CSTR) that enables efficient use of O2 as an oxidant in organic chemistry. Outstanding heat dissipation properties, achieved through integrated jacket cooling and a high surface-to-volume ratio, allow for a safe operation of the exothermic oxidation of 2-ethylhexanal, surpassing previously reported product selectivity. Moving well beyond the proof-of-concept stage, we characterize and illustrate the reactor's potential in the gas-liquid-solid triphasic synthesis of an endoperoxide precursor of antileishmanial agents. The custom-designed magnetic overhead stirring unit provides improved stirring efficiency, facilitating the handling of suspensions and, in combination with the borosilicate gas dispersion plate, leading to an optimized gas-liquid interface. These results underscore the immense potential that lies within the use of mini-CSTR in sustainable chemistry.
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Affiliation(s)
- Ursina Gnädinger
- Institute
of Chemical Technology, Haute École d’Ingénierie
et d’Architecture Fribourg, HES-SO
University of Applied Sciences and Arts Western Switzerland, 1700 Fribourg, Switzerland
| | - Dario Poier
- Institute
of Chemical Technology, Haute École d’Ingénierie
et d’Architecture Fribourg, HES-SO
University of Applied Sciences and Arts Western Switzerland, 1700 Fribourg, Switzerland
| | - Claudio Trombini
- Department
of Chemistry “G. Ciamician”, Alma Mater Studiorum, University of Bologna, Via Selmi 2, 40126 Bologna, Italy
| | - Michal Dabros
- Institute
of Chemical Technology, Haute École d’Ingénierie
et d’Architecture Fribourg, HES-SO
University of Applied Sciences and Arts Western Switzerland, 1700 Fribourg, Switzerland
| | - Roger Marti
- Institute
of Chemical Technology, Haute École d’Ingénierie
et d’Architecture Fribourg, HES-SO
University of Applied Sciences and Arts Western Switzerland, 1700 Fribourg, Switzerland
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2
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Doering M, Trinkies LL, Kieninger J, Kraut M, Rupitsch SJ, Dittmeyer R, Urban GA, Weltin A. In Situ Performance Monitoring of Electrochemical Oxygen and Hydrogen Peroxide Sensors in an Additively Manufactured Modular Microreactor. ACS OMEGA 2024; 9:19700-19711. [PMID: 38708269 PMCID: PMC11064172 DOI: 10.1021/acsomega.4c02210] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/06/2024] [Revised: 03/21/2024] [Accepted: 03/27/2024] [Indexed: 05/07/2024]
Abstract
Miniaturized and microstructured reactors in process engineering are essential for a more decentralized, flexible, sustainable, and resilient chemical production. Modern, additive manufacturing methods for metals enable complex reactor-geometries, increased functionality, and faster design iterations, a clear advantage over classical subtractive machining and polymer-based approaches. Integrated microsensors allow online, in situ process monitoring to optimize processes like the direct synthesis of hydrogen peroxide. We developed a modular tube-in-tube membrane reactor fabricated from stainless steel via 3D printing by laser powder bed fusion of metals (PBF-LB/M). The reactor concept enables the spatially separated dosage and resaturation of two gaseous reactants across a membrane into a liquid process medium. Uniquely, we integrated platinum-based electrochemical sensors for the online detection of analytes to reveal the dynamics inside the reactor. An advanced chronoamperometric protocol combined the simultaneous concentration measurement of hydrogen peroxide and oxygen with monitoring of the sensor performance and self-calibration in long-term use. We demonstrated the highly linear and sensitive monitoring of hydrogen peroxide and dissolved oxygen entering the liquid phase through the membrane. Our measurements delivered important real-time insights into the dynamics of the concentrations in the reactor, highlighting the power of electrochemical sensors applied in process engineering. We demonstrated the stable continuous measurement over 1 week and estimated the sensor lifetime for months in the acidic process medium. Our approach combines electrochemical sensors for process monitoring with advanced, additively manufactured stainless steel membrane microreactors, supporting the power of sensor-equipped microreactors as contributors to the paradigm change in process engineering and toward a greener chemistry.
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Affiliation(s)
- Moritz Doering
- Laboratory
for Sensors, IMTEK − Department of Microsystems Engineering, University of Freiburg, 79110 Freiburg, Germany
- Laboratory
for Electrical Instrumentation and Embedded Systems, IMTEK −
Department of Microsystems Engineering, University of Freiburg, 79110 Freiburg, Germany
| | - Laura L. Trinkies
- Institute
of Micro Process Engineering (IMVT), Karlsruhe
Institute of Technology, 76344 Eggenstein-Leopoldshafen, Germany
| | - Jochen Kieninger
- Laboratory
for Sensors, IMTEK − Department of Microsystems Engineering, University of Freiburg, 79110 Freiburg, Germany
- Laboratory
for Electrical Instrumentation and Embedded Systems, IMTEK −
Department of Microsystems Engineering, University of Freiburg, 79110 Freiburg, Germany
| | - Manfred Kraut
- Institute
of Micro Process Engineering (IMVT), Karlsruhe
Institute of Technology, 76344 Eggenstein-Leopoldshafen, Germany
| | - Stefan J. Rupitsch
- Laboratory
for Electrical Instrumentation and Embedded Systems, IMTEK −
Department of Microsystems Engineering, University of Freiburg, 79110 Freiburg, Germany
| | - Roland Dittmeyer
- Institute
of Micro Process Engineering (IMVT), Karlsruhe
Institute of Technology, 76344 Eggenstein-Leopoldshafen, Germany
| | - Gerald A. Urban
- Laboratory
for Sensors, IMTEK − Department of Microsystems Engineering, University of Freiburg, 79110 Freiburg, Germany
| | - Andreas Weltin
- Laboratory
for Sensors, IMTEK − Department of Microsystems Engineering, University of Freiburg, 79110 Freiburg, Germany
- Laboratory
for Electrical Instrumentation and Embedded Systems, IMTEK −
Department of Microsystems Engineering, University of Freiburg, 79110 Freiburg, Germany
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3
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Zhou S, Zhao Y, Xun Y, Wei Z, Yang Y, Yan W, Ding J. Programmable and Modularized Gas Sensor Integrated by 3D Printing. Chem Rev 2024; 124:3608-3643. [PMID: 38498933 DOI: 10.1021/acs.chemrev.3c00853] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/20/2024]
Abstract
The rapid advancement of intelligent manufacturing technology has enabled electronic equipment to achieve synergistic design and programmable optimization through computer-aided engineering. Three-dimensional (3D) printing, with the unique characteristics of near-net-shape forming and mold-free fabrication, serves as an effective medium for the materialization of digital designs into usable devices. This methodology is particularly applicable to gas sensors, where performance can be collaboratively optimized by the tailored design of each internal module including composition, microstructure, and architecture. Meanwhile, diverse 3D printing technologies can realize modularized fabrication according to the application requirements. The integration of artificial intelligence software systems further facilitates the output of precise and dependable signals. Simultaneously, the self-learning capabilities of the system also promote programmable optimization for the hardware, fostering continuous improvement of gas sensors for dynamic environments. This review investigates the latest studies on 3D-printed gas sensor devices and relevant components, elucidating the technical features and advantages of different 3D printing processes. A general testing framework for the performance evaluation of customized gas sensors is proposed. Additionally, it highlights the superiority and challenges of programmable and modularized gas sensors, providing a comprehensive reference for material adjustments, structure design, and process modifications for advanced gas sensor devices.
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Affiliation(s)
- Shixiang Zhou
- Department of Materials Science and Engineering, National University of Singapore, 117575, Singapore
| | - Yijing Zhao
- Department of Mechanical Engineering, National University of Singapore, 117575, Singapore
| | - Yanran Xun
- Department of Materials Science and Engineering, National University of Singapore, 117575, Singapore
| | - Zhicheng Wei
- Department of Materials Science and Engineering, National University of Singapore, 117575, Singapore
| | - Yong Yang
- Temasek Laboratories, National University of Singapore, 5A Engineering Drive 1, 117411, Singapore
| | - Wentao Yan
- Department of Mechanical Engineering, National University of Singapore, 117575, Singapore
| | - Jun Ding
- Department of Materials Science and Engineering, National University of Singapore, 117575, Singapore
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4
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Fabrication of a Stainless-Steel Pump Impeller by Integrated 3D Sand Printing and Casting: Mechanical Characterization and Performance Study in a Chemical Plant. APPLIED SCIENCES-BASEL 2022. [DOI: 10.3390/app12073539] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/01/2023]
Abstract
The emergence of additive manufacturing is renovating the landscape of available production technologies. In this paper, we describe the fabrication of a closed vane pump impeller (ϕ 206 mm, height 68 mm, weight 4 kg) by binder jetting 3D printing of a sand mould followed by casting using stainless steel 316 to create an identical copy of a part in service in a chemical plant in Tarragona, Spain. The original part was reverse engineered and used to create a sand mould by binder jetting 3D printing on which new impellers were fabricated by casting. Metallographic studies showed an austenitic matrix with 6.3% of ferritic phase and 40 μm × 8 μm ferrite grains without precipitated carbides. The impeller was put into operation in a centrifugal pump at a polyol/polyglycol plant belonging to Dow Chemical Ibérica SL from October 2020 to April 2021. Process variables related to the pump behaviour were compared with the same variables obtained in previous cycles with the original impeller for three different product viscosities (30, 180, and 500 cSt). At 500 cSt, the average current consumption was 9.34 A as compared with the 9.41 A measured with the original impeller. Similarly, the pump pressure remained essentially constant during process operation with both impellers (3.97 bar with the new impeller vs. 3.99 bar with the old). Other monitored parameters (product flow, tank level) were similar in both cases, validating the fabrication strategy from an operational point of view. This work further demonstrated that the implementation of additive manufacturing technologies in chemical process engineering is a useful solution to fabricate spare parts that are difficult to replicate with other technologies, providing consequent economic benefits.
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5
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Gordeev EG, Erokhin KS, Kobelev AD, Burykina JV, Novikov PV, Ananikov VP. Exploring metallic and plastic 3D printed photochemical reactors for customizing chemical synthesis. Sci Rep 2022; 12:3780. [PMID: 35260601 PMCID: PMC8904794 DOI: 10.1038/s41598-022-07583-9] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/01/2022] [Accepted: 02/21/2022] [Indexed: 12/04/2022] Open
Abstract
Visible light photocatalysis is a rapidly developing branch of chemical synthesis with outstanding sustainable potential and improved reaction design. However, the challenge is that many particular chemical reactions may require dedicated tuned photoreactors to achieve maximal efficiency. This is a critical stumbling block unless the possibility for reactor design becomes available directly in the laboratories. In this work, customized laboratory photoreactors were developed with temperature stabilization and the ability to adapt different LED light sources of various wavelengths. We explore two important concepts for the design of photoreactors: reactors for performing multiple parallel experiments and reactors suitable for scale-up synthesis, allowing a rapid increase in the product amount. Reactors of the first type were efficiently made of metal using metal laser sintering, and reactors of the second type were successfully manufactured from plastic using fused filament fabrication. Practical evaluation has shown good accuracy of the temperature stabilization in the range typically required for organic synthesis for both types of reactors. Synthetic application of 3D printed reactors has shown good utility in test reactions-furan C-H arylation and thiol-yne coupling. The critical effect of temperature stabilization was established for the furan arylation reaction: heating of the reaction mixture may lead to the total vanishing of photochemical effect.
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Affiliation(s)
- Evgeniy G Gordeev
- Zelinsky Institute of Organic Chemistry, Russian Academy of Sciences, Leninsky Prospect 47, Moscow, Russia, 119991
| | - Kirill S Erokhin
- Zelinsky Institute of Organic Chemistry, Russian Academy of Sciences, Leninsky Prospect 47, Moscow, Russia, 119991
| | - Andrey D Kobelev
- Zelinsky Institute of Organic Chemistry, Russian Academy of Sciences, Leninsky Prospect 47, Moscow, Russia, 119991
- Lomonosov Moscow State University, Leninskie Gory GSP-1, 1-3, Moscow, Russia, 119991
| | - Julia V Burykina
- Zelinsky Institute of Organic Chemistry, Russian Academy of Sciences, Leninsky Prospect 47, Moscow, Russia, 119991
| | - Pavel V Novikov
- Zelinsky Institute of Organic Chemistry, Russian Academy of Sciences, Leninsky Prospect 47, Moscow, Russia, 119991
| | - Valentine P Ananikov
- Zelinsky Institute of Organic Chemistry, Russian Academy of Sciences, Leninsky Prospect 47, Moscow, Russia, 119991.
- Lomonosov Moscow State University, Leninskie Gory GSP-1, 1-3, Moscow, Russia, 119991.
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6
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Alvarez E, Romero-Fernandez M, Iglesias D, Martinez-Cuenca R, Okafor O, Delorme A, Lozano P, Goodridge R, Paradisi F, Walsh DA, Sans V. Electrochemical Oscillatory Baffled Reactors Fabricated with Additive Manufacturing for Efficient Continuous-Flow Oxidations. ACS SUSTAINABLE CHEMISTRY & ENGINEERING 2022; 10:2388-2396. [PMID: 35223215 PMCID: PMC8864614 DOI: 10.1021/acssuschemeng.1c06799] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/06/2021] [Revised: 01/14/2022] [Indexed: 05/16/2023]
Abstract
Electrochemical continuous-flow reactors offer a great opportunity for enhanced and sustainable chemical syntheses. Here, we present a novel application of electrochemical continuous-flow oscillatory baffled reactors (ECOBRs) that combines advanced mixing features with electrochemical transformations to enable efficient electrochemical oxidations under continuous flow at a millimeter distance between electrodes. Different additive manufacturing techniques have been employed to rapidly fabricate reactors. The electrochemical oxidation of NADH, a very sensitive substrate key for the regeneration of enzymes in biocatalytic transformations, has been employed as a benchmark reaction. The oscillatory conditions improved bulk mixing, facilitating the contact of reagents to electrodes. Under oscillatory conditions, the ECOBR demonstrated improved performance in the electrochemical oxidation of NADH, which is attributed to improved mass transfer associated with the oscillatory regime.
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Affiliation(s)
- Elena Alvarez
- Departamento
de Bioquimica, Biologia Molecular e Inmunologia, Facultad de Quimica, Universidad de Murcia, Campus Reg Excelencia Int Mare Nostrum, E-30100 Murcia, Spain
| | - Maria Romero-Fernandez
- School
of Chemistry, University of Nottingham, University Park, Nottingham NG7 2RD, United Kingdom
| | - Diego Iglesias
- Institute
of Advanced Materials (INAM), Universitat
Jaume I, Avda. Sos Baynat s/n, 12071 Castellon, Spain
| | - Raul Martinez-Cuenca
- Department
of Mechanical Engineering and Construction, Universitat Jaume I, Av. Vicent Sos Baynat s/n, 12071 Castellon, Spain
| | - Obinna Okafor
- Faculty
of Engineering, University of Nottingham, University Park, Nottingham NG7 2RD, United Kingdom
| | - Astrid Delorme
- The GSK Carbon
Neutral Laboratory for Sustainable Chemistry, Jubilee Campus, University of Nottingham, Triumph Road, Nottingham NG7 2TU, United Kingdom
| | - Pedro Lozano
- Departamento
de Bioquimica, Biologia Molecular e Inmunologia, Facultad de Quimica, Universidad de Murcia, Campus Reg Excelencia Int Mare Nostrum, E-30100 Murcia, Spain
| | - Ruth Goodridge
- Faculty
of Engineering, University of Nottingham, University Park, Nottingham NG7 2RD, United Kingdom
| | - Francesca Paradisi
- Department
of Chemistry, Biochemistry and Pharmaceutical Sciences, University of Bern, Freiestrasse 3, 3012 Bern, Switzerland
| | - Darren A. Walsh
- The GSK Carbon
Neutral Laboratory for Sustainable Chemistry, Jubilee Campus, University of Nottingham, Triumph Road, Nottingham NG7 2TU, United Kingdom
| | - Victor Sans
- Institute
of Advanced Materials (INAM), Universitat
Jaume I, Avda. Sos Baynat s/n, 12071 Castellon, Spain
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7
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Lopez-Rodriguez R, Harding MJ, Gibson G, Girard KP, Ferguson S. Design of a Combined Modular and 3D-Printed Falling Film Solution Layer Crystallizer for Intermediate Purification in Continuous Production of Pharmaceuticals. Ind Eng Chem Res 2021; 60:10276-10285. [PMID: 34475633 PMCID: PMC8385708 DOI: 10.1021/acs.iecr.1c00988] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/12/2021] [Revised: 06/13/2021] [Accepted: 06/15/2021] [Indexed: 11/29/2022]
Abstract
A highly scalable combined modular and 3D-printed falling film crystallization device is developed and demonstrated herein; the device uses a small, complex, printed overflow-based film distribution part that ensures formation of a well-distributed heated liquid film around a modular, tubular residence time/crystallizer section, enabling extended residence times to be achieved. A model API (ibuprofen) and impurity (ibuprofen ethyl ester) were used as a test system in the evaluation of the novel crystallizer design. The proposed crystallizer was run using three operational configurations: batch, cyclical batch, and continuous feed, all with intermittent removal of product. Results were suitable for intermediate purification requirements, and stable operation was demonstrated over multiple cycles, indicating that this approach should be compatible with parallel semicontinuous operation for intermediate purification and solvent swap applications in the manufacture of drugs.
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Affiliation(s)
- Rafael Lopez-Rodriguez
- School
of Chemical and Bioprocess Engineering, University College Dublin, Belfield, Dublin 4, Ireland
- SSPC,
The SFI Research Centre for Pharmaceuticals, School of Chemical and
Bioprocess Engineering, University College
Dublin, Belfield, Dublin 4, Ireland
| | - Matthew J. Harding
- School
of Chemical and Bioprocess Engineering, University College Dublin, Belfield, Dublin 4, Ireland
- I-Form,
The SFI Research Centre for Advanced Manufacturing, School of Chemical
and Bioprocess Engineering, University College
Dublin, Belfield, Dublin 4, Ireland
| | - Geoff Gibson
- Pfizer
Ireland Pharmaceuticals, Ringaskiddy, Ireland
| | - Kevin P. Girard
- Pfizer
Inc. Chemical R&D, Groton, Connecticut 06340, United States
| | - Steven Ferguson
- School
of Chemical and Bioprocess Engineering, University College Dublin, Belfield, Dublin 4, Ireland
- SSPC,
The SFI Research Centre for Pharmaceuticals, School of Chemical and
Bioprocess Engineering, University College
Dublin, Belfield, Dublin 4, Ireland
- I-Form,
The SFI Research Centre for Advanced Manufacturing, School of Chemical
and Bioprocess Engineering, University College
Dublin, Belfield, Dublin 4, Ireland
- National
Institute for Bioprocess Research and Training, 24 Foster’s Avenue, Belfield, Blackrock, Co. Dublin A94 X099, Ireland
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8
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Gambacorta G, Sharley JS, Baxendale IR. A comprehensive review of flow chemistry techniques tailored to the flavours and fragrances industries. Beilstein J Org Chem 2021; 17:1181-1312. [PMID: 34136010 PMCID: PMC8182698 DOI: 10.3762/bjoc.17.90] [Citation(s) in RCA: 25] [Impact Index Per Article: 8.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/29/2021] [Accepted: 04/22/2021] [Indexed: 12/28/2022] Open
Abstract
Due to their intrinsic physical properties, which includes being able to perform as volatile liquids at room and biological temperatures, fragrance ingredients/intermediates make ideal candidates for continuous-flow manufacturing. This review highlights the potential crossover between a multibillion dollar industry and the flourishing sub-field of flow chemistry evolving within the discipline of organic synthesis. This is illustrated through selected examples of industrially important transformations specific to the fragrances and flavours industry and by highlighting the advantages of conducting these transformations by using a flow approach. This review is designed to be a compendium of techniques and apparatus already published in the chemical and engineering literature which would constitute a known solution or inspiration for commonly encountered procedures in the manufacture of fragrance and flavour chemicals.
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Affiliation(s)
- Guido Gambacorta
- Department of Chemistry, University of Durham, Stockton Road, Durham, DH1 3LE, United Kingdom
| | - James S Sharley
- Department of Chemistry, University of Durham, Stockton Road, Durham, DH1 3LE, United Kingdom
| | - Ian R Baxendale
- Department of Chemistry, University of Durham, Stockton Road, Durham, DH1 3LE, United Kingdom
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9
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Manufacturing and Application of 3D Printed Photo Fenton Reactors for Wastewater Treatment. INTERNATIONAL JOURNAL OF ENVIRONMENTAL RESEARCH AND PUBLIC HEALTH 2021; 18:ijerph18094885. [PMID: 34064341 PMCID: PMC8125145 DOI: 10.3390/ijerph18094885] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/29/2021] [Revised: 04/28/2021] [Accepted: 05/02/2021] [Indexed: 11/17/2022]
Abstract
Additive manufacturing (AM) or 3D printing offers a new paradigm for designing and developing chemical reactors, in particular, prototypes. The use of 3D printers has been increasing, their performance has been improving, and their price has been reducing. While the general trend is clear, particular applications need to be assessed for their practicality. This study develops and follows a systematic approach to the prototyping of Advanced Oxidation Processes (AOP) reactors. Specifically, this work evaluates and discusses different printable materials in terms of mechanical and chemical resistance to photo-Fenton reactants. Metallic and ceramic materials are shown to be impracticable due to their high printing cost. Polymeric and composite materials are sieved according to criteria such as biodegradability, chemical, thermal, and mechanical resistance. Finally, 3D-printed prototypes are produced and tested in terms of leakage and resistance to the photo-Fenton reacting environment. Polylactic acid (PLA) and wood-PLA composite (Timberfill®) were selected, and lab-scale raceway pond reactors (RPR) were printed accordingly. They were next exposed to H2O2/Fe(II) solutions at pH = 3 ± 0.2 and UV radiation. After 48 h reaction tests, results revealed that the Timberfill® reactor produced higher Total Organic Carbon (TOC) concentrations (9.6 mg·L-1) than that obtained for the PLA reactor (5.5 mg·L-1) and Pyrex® reactor (5.2 mg·L-1), which suggests the interference of Timberfill® with the reaction. The work also considers and discusses further chemical and mechanical criteria that also favor PLA for 3D-printing Fenton and photo-Fenton reactors. Finally, the work also provides a detailed explanation of the printing parameters used and guidelines for preparing prototypes.
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10
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Hapke S, Luinstra GA, Zentel KM. Optimization of a 3D-printed tubular reactor for free radical polymerization by CFD. J Flow Chem 2021. [DOI: 10.1007/s41981-021-00154-5] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/23/2023]
Abstract
AbstractA flow reactor for the complex reaction network of the free radical solution polymerization of n-butyl acrylate was optimized by a combination of kinetic modeling, computational fluid dynamics (CFD) and additive manufacturing. CFD was used to model a flow reactor with SMX mixing elements. An optimized geometry was 3D-printed from polypropylene. The modeled residence time behavior was compared to relevant experiments, giving a validation for the flow behavior of the reactor. A kinetic model for the free radical solution polymerization of n-butyl acrylate (BA) was in addition implemented into the CFD model. It was used to predict the polymerization behavior in the flow reactor and the resulting product properties. The experimental and computational results were in acceptable agreement.
Graphical abstract
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11
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Nyande BW, Mathew Thomas K, Lakerveld R. CFD Analysis of a Kenics Static Mixer with a Low Pressure Drop under Laminar Flow Conditions. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c00135] [Citation(s) in RCA: 10] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Baggie W. Nyande
- Department of Chemical and Biological Engineering, The Hong Kong University of Science and Technology, Clear Water Bay, Kowloon, Hong Kong
| | - Kiran Mathew Thomas
- Department of Chemical and Biological Engineering, The Hong Kong University of Science and Technology, Clear Water Bay, Kowloon, Hong Kong
| | - Richard Lakerveld
- Department of Chemical and Biological Engineering, The Hong Kong University of Science and Technology, Clear Water Bay, Kowloon, Hong Kong
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12
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Maierhofer M, Maier MC, Gruber-Woelfler H, Mayr T. Inline monitoring of high ammonia concentrations in methanol with a customized 3D printed flow cell. J Flow Chem 2021. [DOI: 10.1007/s41981-021-00141-w] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Abstract
AbstractA novel system for inline monitoring of ammonia (NH3) suitable for methanol is presented. An optical ammonia sensor with a response time t90 of 33 s was combined with a tailor-made, 3D printed flow cell and allowed efficient measurements under continuous flow. The optical sensor includes a fluorescent indicator dye that is physically immobilized into a polyurethane hydrogel. A protective layer made of hydrophobic polyether sulfone (PES) shields the ammonia sensitive material against interfering substances and guarantees long-term stability in methanol. The sensor can be read out via a compact phase fluorimeter. Measurements in continuous flow are enabled by a flow cell manufactured via selective laser melting (SLM) of stainless steel. Stainless steel was chosen for the flow cell due to its good heat transfer properties and relatively good chemical resistance of NH3 in methanol. The measurements were successfully carried out with ammonia concentrations between 0.3 and 5.6 mol L− 1 NH3 in methanol at 25 °C up to 80 °C. Additionally, different flow-rates (0.5–2.0 mL min− 1), varying internal pressure (0.5–2.0 bar) as well as reversibility of the measurements at 25 and 60 °C were studied in detail. The sensor did not degrade indicated by sufficient signal and low drift over a period of two weeks, thus indicating the high potential of the novel set-up for real-time measurements in continuous flow applications.
Graphical abstract
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13
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Sivo A, Galaverna RDS, Gomes GR, Pastre JC, Vilé G. From circular synthesis to material manufacturing: advances, challenges, and future steps for using flow chemistry in novel application area. REACT CHEM ENG 2021. [DOI: 10.1039/d0re00411a] [Citation(s) in RCA: 22] [Impact Index Per Article: 7.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/17/2022]
Abstract
We review the emerging use of flow technologies for circular chemistry and material manufacturing, highlighting advances, challenges, and future directions.
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Affiliation(s)
- Alessandra Sivo
- Department of Chemistry
- Materials and Chemical Engineering “Giulio Natta”
- Politecnico di Milano
- IT-20131 Milano
- Italy
| | | | | | | | - Gianvito Vilé
- Department of Chemistry
- Materials and Chemical Engineering “Giulio Natta”
- Politecnico di Milano
- IT-20131 Milano
- Italy
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14
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Bornemann‐Pfeiffer M, Kern S, Maiwald M, Meyer K. Calibration‐Free Chemical Process and Quality Control Units as Enablers for Modular Production. CHEM-ING-TECH 2020. [DOI: 10.1002/cite.202000150] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
Affiliation(s)
- Martin Bornemann‐Pfeiffer
- Bundesanstalt für Materialforschung und -prüfung (BAM) Richard-Willstaetter-Straße 11 12489 Berlin Germany
- Technical University of Berlin Chemical and Process Engineering Fraunhoferstraße 33–36 10587 Berlin Germany
| | - Simon Kern
- Bundesanstalt für Materialforschung und -prüfung (BAM) Richard-Willstaetter-Straße 11 12489 Berlin Germany
- S-PACT GmbH Burtscheider Straße 1 52064 Aachen Germany
| | - Michael Maiwald
- Bundesanstalt für Materialforschung und -prüfung (BAM) Richard-Willstaetter-Straße 11 12489 Berlin Germany
| | - Klas Meyer
- Bundesanstalt für Materialforschung und -prüfung (BAM) Richard-Willstaetter-Straße 11 12489 Berlin Germany
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15
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Fischer-Tropsch studies in a 3D-printed stainless steel microchannel microreactor coated with cobalt-based bimetallic-MCM-41 catalysts. Catal Today 2020. [DOI: 10.1016/j.cattod.2020.02.020] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
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16
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Liao J, Zhang S, Wang Z, Song X, Zhang D, Kumar R, Jin J, Ren P, You H, Chen FE. Transition-metal catalyzed asymmetric reactions under continuous flow from 2015 to early 2020. GREEN SYNTHESIS AND CATALYSIS 2020. [DOI: 10.1016/j.gresc.2020.08.001] [Citation(s) in RCA: 26] [Impact Index Per Article: 6.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/22/2022] Open
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17
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Effect of physical properties of dispersed phase on the residence time distribution in straight capillaries. Chem Eng Sci 2020. [DOI: 10.1016/j.ces.2020.115715] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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18
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Maier MC, Valotta A, Hiebler K, Soritz S, Gavric K, Grabner B, Gruber-Woelfler H. 3D Printed Reactors for Synthesis of Active Pharmaceutical Ingredients in Continuous Flow. Org Process Res Dev 2020. [DOI: 10.1021/acs.oprd.0c00228] [Citation(s) in RCA: 14] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Manuel C. Maier
- Institute of Process and Particle Engineering, Graz University of Technology, Graz, 8010, Austria
- Center for Continuous Flow Synthesis and Processing (CCFLOW), Research Center Pharmaceutical Engineering GmbH (RCPE), Graz, 8010, Austria
| | - Alessia Valotta
- Institute of Process and Particle Engineering, Graz University of Technology, Graz, 8010, Austria
- Center for Continuous Flow Synthesis and Processing (CCFLOW), Research Center Pharmaceutical Engineering GmbH (RCPE), Graz, 8010, Austria
| | - Katharina Hiebler
- Institute of Process and Particle Engineering, Graz University of Technology, Graz, 8010, Austria
| | - Sebastian Soritz
- Institute of Process and Particle Engineering, Graz University of Technology, Graz, 8010, Austria
| | - Kristian Gavric
- Institute of Process and Particle Engineering, Graz University of Technology, Graz, 8010, Austria
| | - Bianca Grabner
- Institute of Process and Particle Engineering, Graz University of Technology, Graz, 8010, Austria
| | - Heidrun Gruber-Woelfler
- Institute of Process and Particle Engineering, Graz University of Technology, Graz, 8010, Austria
- Center for Continuous Flow Synthesis and Processing (CCFLOW), Research Center Pharmaceutical Engineering GmbH (RCPE), Graz, 8010, Austria
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19
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Maier MC, Leitner M, Kappe CO, Gruber-Woelfler H. A modular 3D printed isothermal heat flow calorimeter for reaction calorimetry in continuous flow. REACT CHEM ENG 2020. [DOI: 10.1039/d0re00122h] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/06/2023]
Abstract
The presented continuous flow calorimeter enables process understanding of novel flow syntheses and the use of highly reactive compounds. Adaptation of the calorimeter is possible via 3D printing and due to its modular and expandable design.
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Affiliation(s)
- Manuel C. Maier
- Institute of Process and Particle Engineering
- Graz University of Technology
- Graz
- Austria
- Center for Continuous Flow Synthesis and Processing (CC FLOW)
| | - Michael Leitner
- Institute of Process and Particle Engineering
- Graz University of Technology
- Graz
- Austria
- Center for Continuous Flow Synthesis and Processing (CC FLOW)
| | - C. Oliver Kappe
- Center for Continuous Flow Synthesis and Processing (CC FLOW)
- Research Center Pharmaceutical Engineering GmbH (RCPE)
- Graz
- Austria
- Institute of Chemistry
| | - Heidrun Gruber-Woelfler
- Institute of Process and Particle Engineering
- Graz University of Technology
- Graz
- Austria
- Center for Continuous Flow Synthesis and Processing (CC FLOW)
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20
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Harding MJ, Brady S, O'Connor H, Lopez-Rodriguez R, Edwards MD, Tracy S, Dowling D, Gibson G, Girard KP, Ferguson S. 3D printing of PEEK reactors for flow chemistry and continuous chemical processing. REACT CHEM ENG 2020. [DOI: 10.1039/c9re00408d] [Citation(s) in RCA: 24] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
3D-printed parts in PEEK for flow chemistry and continuous processing produced using fused filament fabrication.
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Affiliation(s)
- Matthew J. Harding
- School of Chemical and Bioprocess Engineering
- University College Dublin
- Dublin 4
- Ireland
- I-form, The SFI Research Centre for Advanced Manufacturing
| | - Sarah Brady
- I-form, The SFI Research Centre for Advanced Manufacturing
- School of Mechanical and Materials Engineering
- University College Dublin
- Dublin 4
- Ireland
| | - Heather O'Connor
- I-form, The SFI Research Centre for Advanced Manufacturing
- School of Mechanical and Materials Engineering
- University College Dublin
- Dublin 4
- Ireland
| | - Rafael Lopez-Rodriguez
- School of Chemical and Bioprocess Engineering
- University College Dublin
- Dublin 4
- Ireland
- SSPC, The SFI Research Centre for Pharmaceuticals
| | - Matthew D. Edwards
- SSPC, The SFI Research Centre for Pharmaceuticals
- School of Chemical and Bioprocess Engineering
- University College Dublin
- Dublin 4
- Ireland
| | - Saoirse Tracy
- School of Agriculture and Food Science
- University College Dublin
- Dublin 4
- Ireland
| | - Denis Dowling
- I-form, The SFI Research Centre for Advanced Manufacturing
- School of Mechanical and Materials Engineering
- University College Dublin
- Dublin 4
- Ireland
| | - Geoff Gibson
- Pfizer Ireland Pharmaceuticals
- Ringaskiddy
- Ireland
| | | | - Steven Ferguson
- School of Chemical and Bioprocess Engineering
- University College Dublin
- Dublin 4
- Ireland
- I-form, The SFI Research Centre for Advanced Manufacturing
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21
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Lee HJ, Roberts RC, Im DJ, Yim SJ, Kim H, Kim JT, Kim DP. Enhanced Controllability of Fries Rearrangements Using High-Resolution 3D-Printed Metal Microreactor with Circular Channel. SMALL (WEINHEIM AN DER BERGSTRASSE, GERMANY) 2019; 15:e1905005. [PMID: 31729122 DOI: 10.1002/smll.201905005] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 09/03/2019] [Revised: 10/27/2019] [Indexed: 05/12/2023]
Abstract
High-resolution 3D-printed stainless steel metal microreactors (3D-PMRs) with different cross-sectional geometry are fabricated to control ultrafast intramolecular rearrangement reactions in a comparative manner. The 3D-PMR with circular channel demonstrates the improved controllability in rapid Fries-type rearrangement reactions, because of the superior mixing efficiency to rectangular cross-section channels (250 µm × 125 µm) which is confirmed based on the computational flow dynamics simulation. Even in case of very rapid intramolecular rearrangement of sterically small acetyl group occurring in 333 µs of reaction time, the desired intermolecular reaction can outpace to the undesired intramolecular rearrangement using 3D-PMR to result in high conversion and yield.
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Affiliation(s)
- Hyune-Jea Lee
- Centre for Intelligent Microprocess of Pharmaceutical Synthesis, Department of Chemical Engineering, POSTECH (Pohang University of Science and Technology), Pohang, 37673, South Korea
| | - Robert C Roberts
- Department of Electrical and Electronic Engineering, The University of Hong Kong, Pokfulam Road, Hong Kong, China
| | - Do Jin Im
- Department of Chemical Engineering, Pukyong National University, Busan, 48513, South Korea
| | - Se-Jun Yim
- Centre for Intelligent Microprocess of Pharmaceutical Synthesis, Department of Chemical Engineering, POSTECH (Pohang University of Science and Technology), Pohang, 37673, South Korea
| | - Heejin Kim
- Department of Chemistry, College of Science, Korea University, Seoul, 02841, South Korea
| | - Ji Tae Kim
- Department of Mechanical Engineering, The University of Hong Kong, Pokfulam Road, Hong Kong, China
| | - Dong-Pyo Kim
- Centre for Intelligent Microprocess of Pharmaceutical Synthesis, Department of Chemical Engineering, POSTECH (Pohang University of Science and Technology), Pohang, 37673, South Korea
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22
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Bennett JA, Campbell ZS, Abolhasani M. Role of continuous flow processes in green manufacturing of pharmaceuticals and specialty chemicals. Curr Opin Chem Eng 2019. [DOI: 10.1016/j.coche.2019.07.007] [Citation(s) in RCA: 27] [Impact Index Per Article: 5.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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23
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Bettermann S, Kandelhard F, Moritz HU, Pauer W. Digital and lean development method for 3D-printed reactors based on CAD modeling and CFD simulation. Chem Eng Res Des 2019. [DOI: 10.1016/j.cherd.2019.09.024] [Citation(s) in RCA: 16] [Impact Index Per Article: 3.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/11/2022]
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24
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3D Printing of Metallic Microstructured Mould Using Selective Laser Melting for Injection Moulding of Plastic Microfluidic Devices. MICROMACHINES 2019; 10:mi10090595. [PMID: 31510027 PMCID: PMC6780298 DOI: 10.3390/mi10090595] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 07/22/2019] [Revised: 09/02/2019] [Accepted: 09/06/2019] [Indexed: 01/08/2023]
Abstract
A new method, a 3D printing technique, in particular, selective laser melting (SLM), has been used to fabricate moulds for the injection moulding of thermoplastic microfluidic chips that are suitable for prototyping and early stage scale-up. The micro metallic patterns are printed on to a pre-finished substrate to form a microstructured mould. The dimensional accuracy, surface morphology, bonding strength between the printed patterns and substrate, as well as the microstructure of micro features were all characterized. A microfluidic mould was successfully printed and used directly for injection moulding of cyclic olefin copolymer (COC) microfluidic chips, which were used subsequently to successfully monitor nitrite concentrations in environmental water. The characterization indicated that this new process can be used for fast fabrication of mould tools for injection moulding/hot embossing microfluidic devices. It is faster, more flexible and less expensive than conventional micro-machining processes, although the accuracy and finish are still needed to improve though process optimization and hybrid SLM and machining processes.
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25
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Hiebler K, Soritz S, Gavric K, Birrer S, Maier MC, Grabner B, Gruber-Woelfler H. Multistep synthesis of a valsartan precursor in continuous flow. J Flow Chem 2019. [DOI: 10.1007/s41981-019-00044-x] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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26
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Kockmann N. A Brief History of Chemical Reactor and Reaction Technology. CHEM-ING-TECH 2019. [DOI: 10.1002/cite.201900001] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/09/2022]
Affiliation(s)
- Norbert Kockmann
- Technische Universität DortmundBCI, Apparatedesign Emil-Figge-Straße 68 44227 Dortmund Germany
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27
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Scotti G, Nilsson SM, Matilainen VP, Haapala M, Boije af Gennäs G, Yli-Kauhaluoma J, Salminen A, Kotiaho T. Simple 3D printed stainless steel microreactors for online mass spectrometric analysis. Heliyon 2019; 5:e02002. [PMID: 31312730 PMCID: PMC6609794 DOI: 10.1016/j.heliyon.2019.e02002] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/10/2018] [Revised: 04/10/2019] [Accepted: 06/20/2019] [Indexed: 12/03/2022] Open
Abstract
A simple flow chemistry microreactor with an electrospray ionization tip for real time mass spectrometric reaction monitoring is introduced. The microreactor was fabricated by a laser-based additive manufacturing technique from acid-resistant stainless steel 316L. The functionality of the microreactor was investigated by using an inverse electron demand Diels-Alder and subsequent retro Diels-Alder reaction for testing. Challenges and problems encountered are discussed and improvements proposed. Adsorption of reagents to the rough stainless steel channel walls, short length of the reaction channel, and making a proper ESI tip present challenges, but the microreactor is potentially useful as a disposable device.
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Affiliation(s)
- Gianmario Scotti
- Drug Research Program, Division of Pharmaceutical Chemistry and Technology, Faculty of Pharmacy, P.O. Box 56 (Viikinkaari 5 E), FI-00014, University of Helsinki, Finland
| | - Sofia M.E. Nilsson
- Drug Research Program, Division of Pharmaceutical Chemistry and Technology, Faculty of Pharmacy, P.O. Box 56 (Viikinkaari 5 E), FI-00014, University of Helsinki, Finland
| | - Ville-Pekka Matilainen
- Laser Processing Research Group, Lappeenranta University of Technology, Tuotantokatu 2, FI-53850, Lappeenranta, Finland
| | - Markus Haapala
- Drug Research Program, Division of Pharmaceutical Chemistry and Technology, Faculty of Pharmacy, P.O. Box 56 (Viikinkaari 5 E), FI-00014, University of Helsinki, Finland
| | - Gustav Boije af Gennäs
- Drug Research Program, Division of Pharmaceutical Chemistry and Technology, Faculty of Pharmacy, P.O. Box 56 (Viikinkaari 5 E), FI-00014, University of Helsinki, Finland
| | - Jari Yli-Kauhaluoma
- Drug Research Program, Division of Pharmaceutical Chemistry and Technology, Faculty of Pharmacy, P.O. Box 56 (Viikinkaari 5 E), FI-00014, University of Helsinki, Finland
| | - Antti Salminen
- Laser Processing Research Group, Lappeenranta University of Technology, Tuotantokatu 2, FI-53850, Lappeenranta, Finland
| | - Tapio Kotiaho
- Drug Research Program, Division of Pharmaceutical Chemistry and Technology, Faculty of Pharmacy, P.O. Box 56 (Viikinkaari 5 E), FI-00014, University of Helsinki, Finland
- Department of Chemistry, Faculty of Science, P.O. Box 55 (A.I. Virtasen aukio 1), FI-00014, University of Helsinki, Finland
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28
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Sulzer P, Lebl R, Kappe CO, Mayr T. Oxygen sensors for flow reactors – measuring dissolved oxygen in organic solvents. REACT CHEM ENG 2019. [DOI: 10.1039/c9re00253g] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/16/2022]
Abstract
We are demonstrating a solvent resistant optical sensor for measuring dissolved oxygen in pressurized micro flow reactors.
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Affiliation(s)
- Philipp Sulzer
- Institute of Analytical Chemistry and Food Chemistry
- Graz University of Technology
- 8010 Graz
- Austria
- Center for Continuous Flow Synthesis and Processing (CC FLOW)
| | - René Lebl
- Institute of Chemistry
- University of Graz
- 8010 Graz
- Austria
- Center for Continuous Flow Synthesis and Processing (CC FLOW)
| | - C. Oliver Kappe
- Institute of Chemistry
- University of Graz
- 8010 Graz
- Austria
- Center for Continuous Flow Synthesis and Processing (CC FLOW)
| | - Torsten Mayr
- Institute of Analytical Chemistry and Food Chemistry
- Graz University of Technology
- 8010 Graz
- Austria
- Center for Continuous Flow Synthesis and Processing (CC FLOW)
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