advanced flow reactors - university of washington€¦ · advanced flow reactors. teaming up...
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Advanced Flow ReactorsTeaming up Chemistry and Chemical Engineer “Greener” Processes and Improved Economics
Frank SchmidtSales Director
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Evolution (Revolution) in Chemical Processing
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Batch process scale up
Time
Cos
t
Lab scale
Kilo Lab
Pilot Plant
Manufacturing plant
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Process develoment benefitsExample: Fine Chemicals and Pharma API production
Discovery Development Production Distribution
Early intermediate Advance Intermediate API
Laboratory Pilot Plant Scale – up Technology transfer large scale production
Laboratory Pilot Plant Scale – up Technology transfer large scale production
Batch Technology
15 -60 months, XX MM$
RIsk on the manufacturing site
Key activity
Development of second generation process
Transfer to manufacturing
Regular production
Scale up failure
Limited scale up, management of numerous batch
Complex transfer to regular production
Final process parameter definition on large scale production
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Fine and Pharma Industries
Laboratory Pilot Plant Scale–up Technology transfer large scale production
Advanced Flow Reactor Technology
8 -15 months, X MM$
Risks at the manufacturing site
Key activities
Development of second generation process
Transfer to manufacturing
Regular production
Scale up failure, no scale up
Limited scale up, management of numerous batch
no limitation
Complex transfer to regular production
no issues
Final process parameter definition for large scale production simple
One tool engineered to fit all needs
Simple and fast PAR, Pilot
Production Banks
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Fluidic modules: concept and library
Reaction layerHeat exchange layer
Heat exchange layer
Mixing 300 microns
Pressure drop1 millimeter Reactants
700 microns
4 mm
Heat transfer
Reactants
Heat exchange fluid
700 microns
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1
10
100
1 000
10 000
100 000
1 000 000
10 000 000
100 000 000
0,01 0,1 1 10 100 10001 cm1 mm 1 m
The Impact of Dimensions
100 μm
Heat transfer U x (S/V)
(kW/m3.K)
Pressure dropSimple tube
(bar)4128
dQ
LP
⋅⋅=
Δπη
Laminar flow
Mixing QualityVillermaux
(%)
100
90
80
450 μm
20 bar
6 mm
80 %
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Corning Fluidic module heat exchange performance
Apparatus Specific area, m2/m3
Volumetric heat transfer coefficient
(MW/m3K)Jacketed batch 2.5 10-3
Batch with external heat exchanger
10 10-2
Shell and tubes (metallic; water/water; 1 m/s)
400 0.2
Plate (metallic, 4 mm spaced; water/water, 1 m/s)
800 1.25
Corning glass fluidic modules
(water/water, ~ 0.7 m/s)
2500 1.7
D. Lavric, Thermal performance of Corning glass microstructures, Proceedings of the Heat Transfer and Fluid Flow in Microscale IIIConference, Hilton Whistler, BC, Canada, ECI international, 2008
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Fluidic modules: concept and library
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AFR evaluation tool: flexible with capability all the way to pilot scale
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Fluidic ModulesAdd-on (insulation…)Labelling
Sensing
Instrumentation (Pressure relief valve…)
Connectors
Interfaces
Tubing
Standard Fittings
Frames
O-ring seals
Engineered reactor components
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Glass Fluidic Modules are the building blocks
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Numbering up: system distribution
Individual feed of each reactor
Passive distribution
Mix system
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Numbering up: system distribution
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Scaling the technology to industrial production in 2 ways:Scale-out = increase the total fluidic channel path length/fluidic moduleScale-up = increase the number of fluidic modules
Gen IProcess
Development andPilot Production
Capable
Gen IIscale-out
Gen IIIscale-out
Scale-up: simple numbering up to full production
Stacking scale-out
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AFR: wide range of throughput (*) for production of Fine, Pharma and Specialty chemicals
g/min 15 160 400 660 1600 3200
kg/h 1 10 25 40 100 200
Tons / 5600h 5 56 140 220 560 1120
Tons / 8000h 7 80 200 320 800 1600
Gen I
Gen II
Gen III (Under development)
T -60°C - 230°CP up to 18 bar
(*) per single reactor
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Broad range of applications• Reactions which have already benefited from Corning Advanced-Flow Reactor
– Alkylation– Amidation– Bromination– Condensation– Chlorination– Metal Organic – Hydrogenation– Oxidation– Nitration– Sulfonation
• In mono or multi phase environments– Miscible liquid feeds– Non miscible feeds – emulsions– Liquid and gas feeds– Suspensions
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NITRATION PLANT – BATCH 400 ton/yr
22.8
0 m
42.80 meter 42.80 meter42.80 meter
22.8
0 m
22.8
0 m
14.8
0 m
30.80 meter
Case 1: Plant Footprint Comparison – Batch vs. ContinuousSelective Nitration
NITRATION PLANT – CONTINUOUS 400 ton/yr
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NITRATION PLANT – 400 tons/year
Case 1: Capex and Opex Comparison – Batch vs. ContinuousSelective Nitration
Opex comparison batch versus continuous
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Proces
s Equip
ment
Solvent
recove
ry
Storage
Utilitie
sCons
tructi
on
Wiring a
nd au
tomati
onEng
ineeri
ngTota
l Plan
t
BatchContinuous
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HYDROGENATION PLANT – 400 tons/year
Case 2: Plant Footprint Comparison – Batch vs. ContinuousSelective Hydrogenation
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HYDROGENATION PLANT – 400 tons/year
Case 2: Capex and Opex Comparison – Batch vs. ContinuousSelective Hydrogenation
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Organo Metallic: 100 tons/year
Case 3: Plant Footprint Comparison – Batch vs. ContinuousOrgano-Metallic
batch
continuos
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Organo Metallic: 100 tons/year
Case 3: Capex and Opex Comparison – Batch vs. ContinuousOrgano-Metallic
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Advanced Flow Reactors: Greener and More Economical