Microfabricated reactors for on-chip heterogeneous catalysis

Microfabricated devices constructed from glass and polydimethylsiloxane with integral heaters are described, which can be used for heterogeneous catalysis reactions. Sulfated zirconia is used as the catalyst in an open channel reactor, with either a syringe pump or electroosmotic flow being used to deliver the reactants. The results clearly demonstrate that very high conversion efficiencies are possible, however, the thermodynamics of the reactions are the same as in bulk systems. Ethanol and hexanol are dehydrated to ethene and hexene, respectively, with conversion efficiencies approaching 100%, and the esterification of ethanol is investigated. Yields of approximately 30% ethyl acetate are obtained by gas chromatographic analysis. This is the first time such a method for fabricating a catalyst micro reactor has been reported, yet it demonstrates sufficient robustness and resistance to leakage. The use of electroosmotic flow in a heated catalyst reactor is a significant advancement in reactor design.