Selection of Microreactors

The continuous flow microreactor is a continuous reaction device that achieves efficient mass and heat transfer and intrinsic safety through a narrow flow channel design. Due to the technological updates and development in recent years and the impetus of the state, it has become a highly anticipated hot technology worldwide. The highly efficient mass and heat transfer capabilities of microreactors enable them to replace approximately 30% of the reactors currently used in production, and can significantly shorten the reaction time and increase the reaction yield. Reactions like nitrification and diazotization, which take a long time and carry high risks in traditional reactors, urgently need to be transformed into microreactors. The special flow channel design at the micrometer level not only ensures efficient mass and heat transfer, but also achieves intrinsic safety of the reaction with a liquid holding capacity as low as a few liters of a single reactor.So, in actual production, how should we select the model based on our own needs? YHChem will take you to have a look at the customization process of the microreactor system.

The first stage is the research phase. During this phase, YHChem will communicate with the client on information and technology to complete the feasibility test. Then comes the development stage. Based on the feasibility test, the process is optimized and the reactor is designed. During the design process, information such as the reaction type, reactants and products is the key to the selection of the microreactor. The final stage is the production phase. After the start-up trial operation, all the data have met the standards. YHChem will deliver the turnkey project to the customer and complete the relevant training and after-sales service.

The most crucial stage among them is the development phase. During this stage, the technical team of YHChem will complete the selection and design of the microreactor based on various conditions of the process:

1. Equipment material:

• Corrosion resistance: Hastelloy is preferred for strong acid/alkali reactions. Organic solvent systems can use 316L stainless steel.
• Light transmittance: Photochemical reactions require optical glass (quartz) or fluoropolymers (such as PFA);

Thermal conductivity: Metallic materials are suitable for strongly exothermic reactions, while non-metallic materials (such as silicon carbide) are used in insulating scenarios.

2. Channel size:

• Micron level (10 to 100 μm) : It has a large specific surface area, high mass and heat transfer efficiency, and is suitable for rapid reactions such as nanoparticle synthesis. However, it has high flow resistance and a high risk of clogging.
• Sub-millimeter level (100-500 μm) : Balancing efficiency and flux, it is suitable for liquid-liquid homogeneous/heterogeneous reactions (such as partial nitrification, sulfonation, etc.), and the particle size needs to be controlled to be less than one-third of the inner diameter of the channel.
• Millimeter level (>500 μm) : It has low flow resistance and is suitable for solid-containing systems (such as catalytic hydrogenation, etc.), but the mass transfer efficiency decreases, and static mixing structure compensation needs to be added.

3. Channel shape:

• Heart-shaped flow channels: During the flow process, the material is repeatedly divided and reorganized, which can achieve efficient laminar diffusion and is more suitable for rapid reactions such as nitrification, sulfonation, and polymerization.
• Rhombic channel: It can enhance the turbulence intensity of the fluid and is suitable for high-viscosity materials.
• T/Y channel: Suitable for the preparation reaction of nanoparticles that generate precipitates.

4. Sealing method:

• Seals: There are various materials such as fluororubber, perfluoroether, and graphite composite materials. Careful selection is required based on environmental corrosion conditions, temperature, pressure, etc.

Integrated sealing: Pressureless sintering, one-piece molding, suitable for high-pressure, highly corrosive or high-purity reactions.

The above are some important steps in the selection process of microreactors. We hope our sharing can be helpful to you. If you have any other questions regarding selection, please feel free to contact the technical team of YHChem. We will provide you with the most sincere service.