Microreactors in Organic Chemistry and Catalysis, Second Edition (2013)
11. Industrial Microreactor Process Development up to Production
11.5. Challenges and Concerns
Concerns about an industrial use of microprocess technology still exist [86]. Process chemists need to be familiarized with the new tool. Often it seems that these soft factors are even more relevant than the hard factors. Nonetheless, the performance of microprocess technology must show up a clear driver in the interplay of operating and capital costs of existing equipment and respective costs on the microflow processing side.
Processes that work best with microreactors are fast and generate high-value materials. This restricts the use currently to such niches [86]. However, it is also more and more recognized that speedup of reactions can be achieved by changes in the chemical processing and synthesis in view that is tailored for microreactors. This is initiated with innovative Novel Process Windows, starting with DBU project cluster in Germany (2002), DBU German Environmental Agency up to recent Factory of the Future projects.
Microprocess technology was initially regarded as a rather radical change in chemical engineering. However, in the past decade more and more companies are dedicating their research to the development of various microreactor-based processes and, upon successful initial studies, building pilot plants for further application of this novel technology. Also, other modern technologies such as microwave organic synthesis, ionic liquids, and supercritical processing are being used jointly with microreactors in order to enable further intensification. In this way, some current limitations of microprocess technology are overcome (e.g., concerning solubility, upper operating temperature, heat supply).
Recent patent review in the field of microtechnology [87] showed a decrease in the number of new microdevices, but an increase in the number of their applications and testing for various processes.
Microprocess technology is strongly knowledge driven. Education and training will play a major role here.
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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