Invenios: micro process technology – chemical process technology of tomorrow

Introduction

Micro process technology in continuous flow systems is an innovative alternative to the large-scale batch production in the chemical industry. Its advantages are a good control of the chemical reactions by the very short diffusion lengths in the micro channels and a very efficient heat exchange due to the high surface to volume ratio. With this it is possible to carry out chemical reactions in new ways which can not be realized in large batch vessels.

Over the years Invenios (formerlt Mikroglas Chemtech GmbH) has developed different processes to microstructure glass material. Glass is an excellent material for components in micro process technology because of its high chemical resistance against corrosive and hazardous chemicals and its optical properties which qualifies it for a wide range of optical analysis purposes.

Products

Invenios has developed a wide range of different mixer and reactor designs to carry out liquid/liquid and gas liquid reactions under controlled flow and temperature conditions. Our main mixing principles are multilamination (see Figure 1) and split&recombine mixers. For droplet formation also different T- and Y-mixer designs are available. These mixers work in flow ranges starting from μl/min up to several ml/min total flow. The standard pressure limit is 3 bar and the working temperature is up to 120°C. For higher temperature and pressure applications special designed modules are available. To extend the residence time it is possible to add a coiled tube to the mixer or to integrate additional volume by an extended residence time channel directly into the glass chip.

Figure 1

Interdigital mixer for multilamination.

For temperature control it is possible to integrate electric heater (heating only), Peltier elements (active cooling and heating), or liquid heat exchanger into the frame or directly the microfluidic component. With the liquid heat exchanger and a proper insulation of the reactor setup it is even possible to reach deep temperatures below -40°C.

Besides the mixing/reaction step it becomes more and more important to also separate solvents or byproducts from the main feed so that one can carry out multi step reactions without switching from continuous to batch processing. Here Invenios developed different modules like settler in different scales, capillary separators and modules with integrated membranes. Furthermore we developed together with the Fraunhofer IST a process to modify the surface properties locally by a plasma process and make the channel hydrophobic.

MikroSyn Initio

To complete the product range Invenios offers different laboratory systems, starting from compact setups just to run a single mixer (MikroSyn Initio) up to fully automated machines for multi step reactions see Figure 2 (MikroSyn Flex). These systems come fully equipped with different pumps (rotary piston pumps, micro gear pumps, syringe pumps and HPLC pumps), sensors (temperature, pressure, optical and chemical), valves and other safety devices. The automation can be realized by different systems like Siemens Simatic or National Instruments LabView.

Figure 2

MikroSyn Initio for liquid/liquid reactions.

References

For further information about the different fields of application please also see the following literature:

• Sabine Huebschmann, Dana Kralisch, Holger Loewe, Denis Breuch, Jan Hauke Petersen, Thomas Dietrich and Ralf Scholz. Decision support towards agile eco-design of microreaction processes by accompanying (simplified) life cycle assessment. Green Chemistry (2011) 13, pp. 1694–1707.

• T.R. Dietrich, A. Freitag. Microreaction equipment for photochemical reactions. ACHEMA Congress, Topical Microchemical Engineering, Frankfurt, Germany, May 11–15, 2009.

• Sandra Hübner, Ursula Bentrup, Uwe Budde, Kai Lovis, Thomas Dietrich, Andreas Freitag, Lukas Küpper, and Klaus Jähnisch. An Ozonolysis-Reduction Sequence for the Synthesis of Pharmaceutical Intermediates in Microstructured Devices. Organic Process Research & Development 2009, 13, 952–960.

• Emma E. Coyle, Michael Oelgemöller. Micro-photochemistry: photochemistry in microstructured reactors. The new photochemistry of the future? Photochemical and Photobiological Sciences, Volume 7, Number 11 (November 2008) 1289–1428.

• T. Fukuyama, Y. Hino, N. Kamata, I. Ryu. Quick Execution of [2+2] Type Photochemical Cycloaddition Reaction by Continuous Flow System Using a Glass-made Microreactor. Chemistry Letters Vol.33, No.11, (2004) 1430–1431.