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Chemical Synthesis in Micro

structured Reactors

Micro and Nanotechnology is currently an area of rapid growth with a wide range of applications.
In the last decade, Micro Reactor Technology (MRT), as a new concept in chemical engineering, has
impressively demonstrated the advantages of micro structured devices for chemical reactions, and was
subject to several positive reviews in its field.

If the two graphs below look similar, a closer look at the x-axis demonstrates the difference between a
regular batch, time resolved chemical processes, and a micro structured surface, where the process is
space resolved!

120 120
100 100
80 80
reactant reactant
60
%

60
%

product product
40 40
20 20
0 0
1 2 3 4 5 6 1 2 3 4 5 6
Fig. 1 time [min] space [cm]
The intrinsic advantage of the small dimensions is the extensive control of the reaction parameters
through:

· An improved surface-area-to-volume ratio

On a typical micro reactor surface, this ratio is about 200 cm2cm-3 compared with 1 cm2cm-3 for a
100ml glass flm2cm-3 for a 1 m3 batch reactor.

This advantage is demonstrated for control over temperature (Fig. 2) and concentration (Fig. 3) with the
simulated neutralization reaction (HCl and NaOH) in a 5 m3 vessel
Fig 2a. Batch: The temperature ranges
form 293.15 K (blue) to 303.15 K (red)

according to the color scale above,

Fig.2b MRT: Reaction of HCl (red,

left) and NaOH (blue, left). Local
temperatures are given according to
the scale (above right) in K (y is the cell
thickness and L the channel length).
(stirring 500 RPM) and a micro structured
Fig. 2a Fig. 2b surface.

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Chemical Synthesis in Micro structured Reactors

This exchange of high heat efficiency allows the performance of high exothermic reactions under isothermal
conditions. The development of hot spots and accumulation of reaction heated within the MR are
suppressed so that undesirable side reactions and fragmentation are hindered.

· Efficient mixing

In addition to the heat transfer, mentioned above, mass transport is also considerably improved in MR.
Mixing in micro reactors can occur through diffusion in between laminar flow layers. This is visualized in Fig.
3 for the same reaction as in Fig. 2.

Batch: concentration equivalents (ranging from 0.8 (blue) to 1.2 (red) according to the color scale top left

Fig. 3b. MRT: Compound B is injected (inlet) to a flow of compound A (blue). The green color indicates the
1:1 mixture

Fig. 3b

Fig. 3a

· Small reaction volume

Process parameter such as pressure, temperature, residence time and

flow rate are easily controlled in reactions that take place in small volumes.
The hazard potential of strongly exothermic or explosive reactions can also
be drastically reduced. This system also provides higher safety with toxic
substances or higher operating pressures.

These opportunities could be used most favorably in kinetic controlled

reaction processes. Fig. 4 shows the classical textbook graph.

This meets the most common thinking of organic chemists to discuss

product distributions. In this example product C is favored if the activation
energy provided to the reaction is limited. Fig 5. Demonstrates the
importance of temperature quality to control selectivity under kinetic control
of reactions Fig. 4

MRT is a perfect tool for fast process engineering to acquire information, which allows a safe and
fast transfer to pilot or production scale.

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Chemical Synthesis in Micro structured Reactors

But the “big picture” of this fascinating technology

is a new thinking for production concepts, which
supersedes this transfer. MRT means continuous
processing (24 hours per day 7 days a week).
Depending on demand MR or such subunits can
run in parallel (“numbering-up” concept) and
therefore no further development activity is needed
for a process which is performed in a micro reactor
once.

Sigma-Aldrich introduced this technology a couple

of years ago. An overview of processes based on
the advantages of the technology will be given.

Fig. 5

References:

• K. Jahnisch, V. Hessel, H. Löwe, M. Baerns, Angew. Chem. Int. Ed. 2004, 43, 406.

• P. Watts, S. Haswell Chem. Eng. Technol. 2005, 28, 290.

• T. Schwalbe, V. Autze, G. Wille CHIMIA 2002, 56, 636

• T.M. Floyd, M.W. Kopp, S.L. Firebauch, K. F. Jensen, M.A. Schmidt Proceedings of IMRET 3, Ed. W. Ehrfeld Springer Verlag, Berlin,
Gemany, 2000, p.171.

• R.D. Chambers, M.A. Fox, D. Holling, T. Nakamo. T. Okazoe, G. Sanford Lab. Chip, 2005, 5,191

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