Modular MicroReactor Technology - A Novel Approach for Process Intensification from Lab to Production

Micro process technology enables new pathways for the development of economical, innovative and intensified processes in the chemical industry. Modular Microreaction technology provides clear advantages over conventional process technology through a.) short mixing time, b.) high heat transfer rates, c.) inherent safety of small hold-up, d.) precise control of reaction time and e.) faster scale-up/time-to-market.

For example: microstructured devices have up to three orders of magnitude higher surface-to-volume ratio compared to conventional apparatus. This results in intensified heat transfer. Microreactors are an excellent solution for extremely fast and highly exothermic or endothermic reactions. These reactions can be much better controlled in a microreactor and avoid the possibility of hot spots. This has translated to higher yield, higher selectivity, safer operation, and new pathways for many reactions.

The Modular Microreaction System, which will be presented, has been demonstrated for liquid, gas-liquid and gas phase reactions and also for heterogeneous reactions. Process development can be done efficiently and quickly in the laboratory scale microreactor unit. At the point of scale-up a module with more channels is employed. Identical process results are assured in the pilot and production stage as the physical condition in each channel is still the same. The metalbased micro-fluidic modules can support unit operations of reaction, heat transfer and mixing.

The Miprowa [high throughput] series module is capable to support mixing, heat exchange and reaction simultaneously, and enables fast scale-up from lab to production. Fixed-bed microreactor modules can be used to develop and optimize solid-catalyzed gas and liquid phase processes.

The presentation will introduce the microreactors conceptually, discuss their advantages, highlight the packed bed microreactor modules and Miprowa high throughput reactors, and share examples of their application.