Flow chemistry using milli- and microstructured reactors-from conventional to novel process windows.

Area of Science:

• Chemical Engineering
• Process Chemistry
• Reaction Engineering

Background:

• The chemical industry continuously seeks process optimization for safety, energy efficiency, and novel synthesis routes.
• Sustainable development and Green Chemistry principles drive innovation in chemical manufacturing.
• Existing processes can be improved by applying unconventional, harsh process conditions.

Purpose of the Study:

• To review the applicability of Novel Process Windows on selected chemical reactions using microreactor technology.
• To demonstrate how milli- and microstructured devices enable previously inapplicable process conditions.
• To highlight the benefits of Novel Process Windows in chemical synthesis and process optimization.

Main Methods:

• Review of published works from IMM focusing on Novel Process Windows.
• Discussion of microreactor characteristics: mass/heat transfer, mixing.
• Presentation of chemical reactions benefiting from Novel Process Windows in microstructured devices.

Main Results:

• Microreactors facilitate Novel Process Windows (elevated pressure, temperature, thermal runaway) for enhanced reaction performance.
• Application of Novel Process Windows in microstructured devices leads to significant process improvements.
• Milli- and microstructured reactors offer advantages in catalyst screening and particle synthesis control.

Conclusions:

• Novel Process Windows, when implemented in microstructured reactors, offer a powerful approach to improve chemical processes.
• Microreactor technology enables the safe and efficient application of extreme process conditions.
• This approach supports the chemical industry's goals for high-value chemical synthesis and sustainable practices.