Microreactors in Organic Chemistry and Catalysis, Second Edition (2013)

9.7. Conclusions and Outlook

Two classes of gas–liquid microchannel reactors were developed in the past years – continuous-phase contacting falling film, overlapping channel, mesh, and annular flow approaches, and dispersed-phase contacting by Taylor flow reactors, micromixers for bubble and foam formation, and miniaturized packed bed microreactors, which follow classical trickle-bed operation at smaller scale. Recently integration of operations inside a microdevice has been studied and led to the development of membrane microreactors.

Gas–liquid–solid processes are possible by using either wall-coated catalyst or mini-packed beds. Numerous applications have demonstrated process intensification in terms of selectivity, space-time yield, and safety by use of gas–liquid microreactors, including fluorinations, chlorination, hydrogenations, sulfonations, photooxidations, and so on. This is achieved by enhanced mass transfer via the interface and through formation of thin liquid layers, which also give better transfer and allow conducting photochemical reactions more efficiently. Operation is now possible in new process windows with very aggressive reactants such as elemental fluorine or even under explosive conditions.

The transfer of laboratory process development to pilot-scale is not as much practiced so far as compared to the liquid-phase fine-chemical reactions carried out by microprocess technology. This is largely because of open issues on fluid distribution and the fact that throughputs are often not that large as given for liquid-phase devices, for example, stemming from the need to make thin films in the falling film microreactor. However, there are several commercialized gas–liquid microprocesses, showing that laboratory investigations are completed and new reactor technology is available. Pilot scale falling-film, packed bed, and tube in tube microreactors have been developed recently, which further extend the technological offer for future use.

One example for pilot-scale operation has been already given for the fluorination and the direct synthesis of hydrogen peroxide is on a similar way.

This update, compared to the previous issue, includes more relevant gas–liquid reactions performed in microdevices. This proves the acceptance of the technology and growing research interest in this field. On the other hand, few new microreactor concepts have been developed last five years. This is in agreement with the general attitude that microreactors are well-developed technology and that attention should be redirected to their scaling up and applications.

Acknowledgement

This work is funded by the EU project POLYCATunder grant agreement No. CP-IP 246095-2 of the European Community's Seventh Framework Program and by the ERC Advanced Grant “Novel Process Windows” of Prof. Dr. Volker Hessel at Eindhoven University of Technology (TU/e) in the Netherlands.

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