A microreactor or microstructured reactor or microchannel reactor is a device in which chemical reactions take place in a confinement with typical lateral dimensions below 1 mm; the most typical form of such confinement are microchannels. Microreactors are studied in the field of micro process engineering, together with other devices (such as micro heat exchangers) in which physical processes occur. The microreactor is usually a continuous flow reactor (contrast with/to a batch reactor). Microreactors can offer many advantages over conventional scale reactors, including improvements in energy efficiency, reaction speed and yield, safety, reliability, scalability, on-site/on-demand production, and a much finer degree of process control.
History Gas-phase microreactors have a long history but those involving liquids started to appear in the late 1990s. Static micro mixers as split-and-recombine structuresN. Schwesinger et al. J. Micromech. Microeng. 6 (1996), 99-102 became particular important for micro reaction technology. Chip-based flow thermocylers for PCR were early examples of thermal microreactors for liquid processes.V. Baier et al.: Miniaturized Flow Thermocycler (WO-9610456-A1; DE 4435107 C1 (30.9.1994/4.4.1996))M.U. Kopp et al., Science 280 (1998), 1046–1048I. Schneegaß et al., Lab Chip 1 (2001), 42–49 Other examples are micro flow-through chip calorimeters.J.M. Köhler, M. Zieren, Thermochim. Acta, 310 (1998) 25–35V. Baier et al. Sensors and Actuators A Physical 123 (2005), 354-359 One of the first microreactors with embedded high performance heat exchangers were made in the early 1990s by the Central Experimentation Department (Hauptabteilung Versuchstechnik, HVT) of Forschungszentrum Karlsruhe in Germany, using mechanical micromachining techniques that were a spinoff from the manufacture of separation nozzles for uranium enrichment. As research on nuclear technology was drastically reduced in Germany, microstructured heat exchangers were investigated for their application in handling highly exothermic and dangerous chemical reactions. This new concept, known by names as microreaction technology or micro process engineering, was further developed by various research institutions. An early example from 1997 involved that of azo couplings in a pyrex reactor with channel dimensions 90 micrometres deep and 190 micrometres wide.
Benefits Using microreactors is somewhat different from using a glass vessel. These reactors may be a valuable tool in the hands of an experienced chemist or reaction engineer:
Microreactors typically have heat exchange coefficients of at least 1 megawatt per cubic meter per kelvin, up to 500 MW m−3 K−1 vs. a few kilowatts in conventional glassware (1 L flask ~10 kW m−3 K−1). Thus, microreactors can remove heat much more efficiently than vessels and even critical reactions such as nitrations can be performed safely at high temperatures. Hot spot temperatures as well as the duration of high temperature exposition due to exothermicity decreases remarkably. Thus, microreactors may allow better kinetic investigations, because local temperature gradients affecting reaction rates are much smaller than in any batch vessel. Heating and cooling a microreactor is also much quicker and operating temperatures can be as low as −100 °C. As a result of the superior heat transfer, reaction temperatures may be much higher than in conventional batch-reactors. Many low temperature reactions as organo-metal chemistry can be performed in microreactors at temperatures of −10 °C rather than −50 °C to −78 °C as in laboratory glassware equipment. Microreactors are normally operated continuously. This allows the subsequent processing of unstable intermediates and avoids typical batch workup delays. Especially low temperature chemistry with reaction times in the millisecond to second range are no longer stored for hours until dosing of reagents is finished and the next reaction step may be performed. This rapid work up avoids decay of precious intermediates and often allows better selectivities. Continuous operation and mixing causes a very different concentration profile when compared with a batch process. In a batch, reagent A is filled in and reagent B is slowly added. Thus, B encounters initially a high excess of A. In a microreactor, A and B are mixed nearly instantly and B won't be exposed to a large excess of A. This may be an advantage or disadvantage depending on the reaction mechanism - it is important to be aware of such different concentration profiles. Although a bench-top microreactor can synthesize chemicals only in small quantities, scale-up to industrial volumes is simply a process of multiplying the number of microchannels. In contrast, batch processes too often perform well on R&D bench-top level but fail at batch pilot plant level. Pressurisation of materials within microreactors (and associated components) is generally easier than with traditional batch reactors. This allows reactions to be increased in rate by raising the temperature beyond the boiling point of the solvent. This, although typical Arrhenius behaviour, is more easily facilitated in microreactors and should be considered a key advantage. Pressurisation may also allow dissolution of reactant gasses within the flow stream.
Challenges Although there have been reactors made for handling particles, microreactors generally do not tolerate particulates well, often clogging. Clogging has been identified by a number of researchers as the biggest hurdle for microreactors being widely accepted as a beneficial alternative to batch reactors. So far, the so-called microjetreactor and literature cited therein is free of clogging by precipitating products. Gas evolved may also shorten the residence time of reagents as volume is not constant during the reaction. This may be prevented by application of pressure. Mechanical pumping may generate a pulsating flow which can be disadvantageous. Much work has been devoted to development of pumps with low pulsation. A continuous flow solution is electroosmotic flow (EOF). The logistics issue and enhanced pressure drop across microreactor limits its applicability in large-scale production units. However, clean solutions are handled well in microreactors. The scale-up of production rates and leakage are quite challenging in case of microreactor. Recently, so called nanoparticle immobilized reactors are developed to solve logistics and scale-up issues, associated with the microreactors. Typically, reactions performing very well in a microreactor encounter many problems in vessels, especially when scaling up. Often, the high area to volume ratio and the uniform residence time cannot easily be scaled. Corrosion imposes a bigger issue in microreactors because area to volume ratio is high. Degradation of few μm may go unnoticed in conventional vessels. As typical inner dimensions of channels are in the same order of magnitude, characteristics may be altered significantly.
T reactors One of the simplest forms of a microreactor is a 'T' reactor. A 'T' shape is etched into a plate with a depth that may be 40 micrometres and a width of 100 micrometres: the etched path is turned into a tube by sealing a flat plate over the top of the etched groove. The cover plate has three holes that align to the top-left, top-right, and bottom of the 'T' so that fluids can be added and removed. A solution of reagent 'A' is pumped into the top left of the 'T' and solution 'B' is pumped into the top right of the 'T'. If the pumping rate is the same, the components meet at the top of the vertical part of the 'T' and begin to mix and react as they go down the trunk of the 'T'. A solution of product is removed at the base of the 'T'.
Applications
Synthesis Microreactors can be used to synthesise material more effectively than current batch techniques allow. The benefits here are primarily enabled by the mass transfer, thermodynamics, and high surface area to volume ratio environment as well as engineering advantages in handling unstable intermediates. Microreactors are applied in combination with photochemistry, electrosynthesis, multicomponent reactions and polymerization (for example that of butyl acrylate). It can involve liquid-liquid systems but also solid-liquid systems with for example the channel walls coated with a heterogeneous catalyst. Synthesis is also combined with online purification of the product. Following green chemistry principles, microreactors can be used to synthesize and purify extremely reactive Organometallic Compounds for ALD and CVD applications, with improved safety in operations and higher purity products.Method of Preparing Organometallic Compounds Using Microchannel Devices, 2009, Francis Joseph Lipiecki, Stephen G. Maroldo, Deodatta Vinayak Shenai-Khatkhate, and Robert A. Ware, US 20090023940Purification Process Using Microchannel Devices, 2009, Francis Joseph Lipiecki, Stephen G. Maroldo, Deodatta Vinayak Shenai-Khatkhate, and Robert A. Ware, US 20090020010
In microreactor studies a Knoevenagel condensation was performed with the channel coated with a zeolite catalyst layer which also serves to remove water generated in the reaction. The same reaction was performed in a microreactor covered by polymer brushes.
A Suzuki reaction was examined in another study with a palladium catalyst confined in a polymer network of polyacrylamide and a triarylphosphine formed by interfacial polymerization:
The combustion of propane was demonstrated to occur at temperatures as low as 300 °C in a microchannel setup filled up with an aluminum oxide lattice coated with a platinum / molybdenum catalyst:
Enzyme catalyzed polymer synthesis Enzymes immobilized on solid supports are increasingly used for greener, more sustainable chemical transformation processes. > enabled to perform heterogeneous reactions in continuous mode, in organic media, and at elevated temperatures. Using microreactors, enabled faster polymerization and higher molecular mass compared to using batch reactors. It is evident that similar microreactor based platforms can readily be extended to other enzyme-based systems, for example, high-throughput screening of new enzymes and to precision measurements of new processes where continuous flow mode is preferred. This is the first reported demonstration of a solid supported enzyme-catalyzed polymerization reaction in continuous mode.
Analysis Microreactors can also enable experiments to be performed at a far lower scale and far higher experimental rates than currently possible in batch production, while not collecting the physical experimental output. The benefits here are primarily derived from the low operating scale, and the integration of the required sensor technologies to allow high quality understanding of an experiment. The integration of the required synthesis, purification and analytical capabilities is impractical when operating outside of a microfluidic context.
NMR
Researchers at the Radboud University Nijmegen and Twente University, the Netherlands, have developed a microfluidic high-resolution NMR flow probe. They have shown a model reaction being followed in real-time. The combination of the uncompromised (sub-Hz) resolution and a low sample volume can prove to be a valuable tool for flow chemistry.
Infrared spectroscopy
Mettler Toledo and Bruker Optics offer dedicated equipment for monitoring, with attenuated total reflectance spectrometry (ATR spectrometry) in microreaction setups. The former has been demonstrated for reaction monitoring. The latter has been successfully used for reaction monitoring and determining dispersion characteristics of a microreactor.
Academic research