(594e) A Miniature CSTR Platform for Continuous Processing of Multiphase Systems
- Conference: AIChE Annual Meeting
- Year: 2017
- Proceeding: 2017 Annual Meeting
- Group: Pharmaceutical Discovery, Development and Manufacturing Forum
- Time: Wednesday, November 1, 2017 - 4:43pm-5:05pm
Here, we present a new miniaturized continuously stirred-tank reactor (CSTR) for continuous processing of multiphase systems. The design, with the feature of plug-and-play, takes efficient mass and heat transfer, chemical compatibility, and ease to fabricate and clean into account. Single-phase residence time distribution (RTD) measurements of the CSTR unit reveal nearly ideal CSTR mixing. It also has the capability to tune the RTD by connecting several units in series to achieve approximate plug flow reactor (PFR) RTD, which gives the flexibility to optimize the selectivity based on the reaction kinetics.
Two versions of miniature CSTRs were developed for: (i) solid handling in flow, and (ii) high-performance liquid-liquid mixing.
Solid handling CSTR: employing the non-stick polytetrafluoroethylene (PTFE) as the reactor body material with minimized inter-unit connection enables the CSTR to continuously handle high-concentrated slurries for hours without significant signs of clogging. Two solid-forming reactions, (i) glyoxal reacting with cyclohexylamine to form N,Nâ²-dicyclohexylethylenediimine, and (ii) sulfonylation of 2-octanol with methanesulfonyl chloride, demonstrate its practical usefulness as a powerful for flow chemistry field.
High-performance liquid-liquid CSTR: incorporating the magnetic-coupling as the driving force to provide external agitation inside the confined reactor space gives the possibility to generate extraordinary two-phase mixing performance without losing the capability to seal the reactor. We demonstrate the reactor with a comparable liquid-liquid mass transfer coefficient to Corning Advance-flow Reactor, which is the state-of-the-art among commercial reactors. More importantly, it gets around the problem of coupling of flowrate and mixing, and is capable to accommodate reaction kinetics from seconds to hours. Phase transfer catalyzed reactions were demonstrated in this newly designed CSTR, with the corresponding kinetic model developed for Makosza phase-transfer mechanism. In addition, the success of carrying out biphasic Suzuki-Miyaura reactions further validates its suitability for the pharmaceutical applications.