Abstract
Is it possible to miniaturize a chemical plant? Some strategies, such as the process intensification, sustain that the advancements in equipment and production techniques could substantially decrease the equipment size/production capacity ratio, energy consumption and waste generation, resulting in more economic and sustainable operations and consequently reducing the chemical plant size. However, large reductions of equipment volume represent a major challenge for the conventional technologies. In this context, Microfluidics represents a promising technology in the field of system miniaturization. Accordingly, the present research evaluated the concept of process intensification and its relationship with Microfluidics. Initially, the definition and the classification of process intensification were described, following by the explanation of the Microfluidics, highlighting scale-up strategies and examples using miniaturized systems. Afterward, a methodology for miniaturized devices development for process intensification using numerical simulations was shown. Finally, the conclusions are exposed.
Funding statement: This work was supported by the Conselho Nacional de Desenvolvimento Científico e Tecnológico, 10.13039/501100003593, Grant Number: 404760/2016-3, Fundação de Amparo à Pesquisa do Estado de São Paulo, 10.13039/501100001807, Grant Number: 2016/20842-4
Acknowledgements
The authors would like to thank the National Postdoctoral Program (PNPD/Capes), the Unicamp Scholarship Program, the Microfabrication Laboratory (Proposal LMF-19844) and the financial support provided by CNPq (National Council for Scientific and Technological Development, Process 404760/2016-3), FAPESP (São Paulo Research Foundation, Process 2013/25850-7 and Process 2016/20842-4) and FAPEMIG (Minas Gerais Research Foundation, Process APQ-02144-17).
References
Al-Rawashdeh, M., J. Zalucky, C. Müller, T. A. Nijhuis, and J. C. Schouten. 2013. “Phenylacetylene Hydrogenation over [Rh(Nbd)(Pph3)2]Bf4 Catalyst in a Numbered-Up Microchannels Reactor.” Industrial & Engineering Chemistry Research 52: 11516–26.10.1021/ie4009277Suche in Google Scholar
Ansari, M. A., and K-Y. Kim. 2009. “A Numerical Study of Mixing in A Microchannel with Circular Mixing Chambers.” AIChE Journal 55(9): 2217–25.10.1002/aic.11833Suche in Google Scholar
AntiqueTech.2013. “The ENIAC vs. The Cell Phone.” Available in: Accessed November 14, 2017. <http://www.antiquetech.com/?page_id=1438/>.Suche in Google Scholar
Billo, R. E., C. R Oliver, R. Charoenwat, B. H. Dennis, P. A. Wilson, J. W. Priest, and H. Beardsley. 2015. “A Cellular Manufacturing Process for A Full-Scale Biodiesel Microreactor.” Journal of Manufacturing Systems 37: 409–16.10.1016/j.jmsy.2014.07.004Suche in Google Scholar
Cardoso, S., D. C. Leitao, T. M. Dias, J. Valadeiro, M. D. Silva, A. Chicharo, V. Silveiro, J. Gaspar, and P. P Freitas. 2017. “Challenges and Trends in Magnetic Sensor Integration with Microfluidics for Biomedical Applications.” Journal of Physics D: Applied Physics. 50. DOI: doi.org/10.1088/1361-6463/aa66ec.10.1088/1361-6463/aa66ecSuche in Google Scholar
Elvira, K. S., X. C. Solvas, R. C. R. Wootton, and A. J. Mello. 2013. “The Past, Present and Potential for Microfluidic Reactor Technology in Chemical Synthesis.” Nature Chemistry 5: 905–15.10.1038/nchem.1753Suche in Google Scholar PubMed
Fogler, H. S. 2006. Elements of Chemical Reaction Engineering. Upper Saddle River, NJ: Prentice Hall PTR.Suche in Google Scholar
Guan, G., M. Teshima, C. Sato, S.M. Son, M.F. Irfan, K. Kusakabek, N. Ikeda, and T.-J. Lin. 2010. “Two-Phase Flow Behavior in Microtube Reactors during Biodiesel Production from Waste Cooking Oil.” AIChE Journal 56(5): 1383–90.10.1002/aic.12042Suche in Google Scholar
Han, T., L. Zhang, H. Xu, and J. Xuan. 2017. “Factory-On-Chip: Modularised Microfluidic Reactors for Continuous Mass Production of Functional Materials.” Chemical Engineering Journal 326: 765–73.10.1016/j.cej.2017.06.028Suche in Google Scholar
Institution of Chemical Engineers (IChemE). 2007. “A Roadmap for twenty-first Century Chemical Engineering.” Available in: Accessed November 14, 2017. <http://www.gospi.fr/IMG/pdf/roadmap2007-GP.pdf/>.Suche in Google Scholar
Kiss, A. A. 2014. Process Intensification Technologies for Biodiesel Production – Reactive Separation Process, 1st ed. Cham Heidelberg New York Dordrecht London: Springer.10.1007/978-3-319-03554-3Suche in Google Scholar
Kockmann, C., T. Kiefer, M. Engler, and P. Woias. 2006. “Convective Mixing and Chemical Reactions in Microchannels with High Flow Rates.” Sensors and Actuators B 117: 495–508.10.1016/j.snb.2006.01.004Suche in Google Scholar
Lee, C-Y., and L-M. Fu. 2018. “Recent Advances and Applications of Micromixers.” Sensors and Actuators B: Chemical 259: 677–702.10.1016/j.snb.2017.12.034Suche in Google Scholar
Lee, C-Y., W-T. Wang, C-C. Liu, and L-M. Fu. 2016. “Passive Mixers in Microfluidic Systems: A Review.” Chemical Engineering Journal 288: 146–60.10.1016/j.cej.2015.10.122Suche in Google Scholar
Lo, R. C. 2013. “Application of Microfluidics in Chemical Engineering.” Chemical Engineering & Process Techniques 1: 1002.Suche in Google Scholar
Lutze, P., R. Gani, and J. M. Woodley. 2010. “Process Intensification: A Perspective on Process Synthesis.” Chemical Engineering and Processing: Process Intensification 49: 547–58.10.1016/j.cep.2010.05.002Suche in Google Scholar
Melo, J. 2010. “Usinas de Biodiesel em Pernambuco. 30 de abr.” Avaliable in: Accessed November 16, 2017. https://www.biodieselbr.com/noticias/colunistas/convidado/usinas-biodiesel-pernambuco-300410.htm.Suche in Google Scholar
Nagaki, A., K. Hirose, O. Tonomura, S. Taniguchi, T. Taga, S. Hasebe, N. Ishizuka, and J. Yoshida. 2016. “Design of a Numbering-Up System of Monolithic Microreactors and Its Application to Synthesis of a Key Intermediate of Valsartan.” Organic Process Research & Development 20: 687–91.10.1021/acs.oprd.5b00414Suche in Google Scholar
Nguyen, N-T. 2012. Micromixers. Fundamentals, Design and Fabrication, 2nd ed. Waltham, MA, USA: William Andrew Applied Science Publishers/Elsevier. 353.Suche in Google Scholar
Nguyen, N-T., and S. T. Wereley. 2006. Fundamentals and Applications of Microfluidics. Boston/London: Publishing House Artech House.Suche in Google Scholar
Pohar, A., and I. Plazl. 2009. “Process Intensification through Microreactor Application.” Chemical and Biochemical Engineering Quarterly 23: 537–44.Suche in Google Scholar
Qin, Y., W. He, M. Su, Z. Fang, J. Gu, P. Ouyang, K. Guo, et al. 2016. “Continuous Synthesis of Ginkgolide B Derivatives in a Micro-Flow System.” Tetrahedron Letters 57: 1243–46.10.1016/j.tetlet.2016.02.018Suche in Google Scholar
Ramshaw, C. 1995. “The Incentive for Process Intensification.” Proceedings, 1st Intl. Conf. Proc. Intensif. for Chem. Ind., London, 18, 1.Suche in Google Scholar
Sakuth, M., D. Reusch, and R. Janowsky. 2008. Reactive Distillation. Ullmann’s Encyclopedia of Industrial Chemistry. doi: 10.1002 / 14356007.c22_c01.pub2.10.1002/14356007.c22_c01.pub2Suche in Google Scholar
Santana, H. S., G. B. Sanchez, and O. P. Taranto. 2017a. “Evaporation of Excess Alcohol in Biodiesel in a Microchannel Heat Exchanger with Peltier Module.” Chemical Engineering Research & Design 124: 20–28.10.1016/j.cherd.2017.05.022Suche in Google Scholar
Santana, H. S., J. L. Silva Jr., and O. P. Taranto. 2015. “Numerical Simulations of Biodiesel Synthesis in Microchannels with Circular Obstructions.” Chemical Engineering and Processing: Process Intensification 98: 137–46.10.1016/j.cep.2015.10.011Suche in Google Scholar
Santana, H. S., D. S. Tortola, E. M. Reis, J. L. Silva, and O. P. Taranto. 2016. “Transesterification Reaction of Sunflower Oil and Etanol for Biodiesel Synthesis in Microchannel Reactor: Experimental and Simulation Studies.” Chemical Engineering Journal 302: 752–62.10.1016/j.cej.2016.05.122Suche in Google Scholar
Santana, H. S., D. S. Tortola, J. L. Silva, and O. P. Taranto. 2017b. “Biodiesel Synthesis in Micromixer with Static Elements.” Energy Conversion and Management 141: 28–39.10.1016/j.enconman.2016.03.089Suche in Google Scholar
Silva Jr., J. L, H. S. Santanta, G. B. Sanchez, and O. P. Taranto. 2017. “Numerical Simulation of Excess Ethanol Evaporation from Biodiesel in a Micro Heat-Exchanger.” Chemical Engineering Transactions 57: 1123–28.Suche in Google Scholar
Skardal, A., S.V. Murphy, M. Devarasetty, I. Mead, H-W. Kang, Y-J. Seol, Y.S. Zhang, et al. 2017. “Multi-Tissue Interactions in an Integrated Three-Tissue Organ-On-A-Chip Platform.” Scientific Reports 7(1): 8837.10.1038/s41598-017-08879-xSuche in Google Scholar PubMed PubMed Central
Snytnikov, P. V., D. I. Potemkin, E. V. Rebrov, V. A. Sobyanin, V. Hessel, and J. C. Schouten. 2010. “Design, Scale-Out, and Operation of a Microchannel Reactor with a Cu/CeO2-x Catalytic for Preferential CO Oxidation.” Chemical Engineering Journal 160: 923–29.10.1016/j.cej.2009.12.019Suche in Google Scholar
Solehati, N., J. Bae, and A. P. Sasmito. 2014. “Numerical Investigation of Mixing Performance in Microchannel T-Junction with Wavy Structure.” Computer & Fluids 96: 10–14.10.1016/j.compfluid.2014.03.003Suche in Google Scholar
Solorzano, I. O., A. U. L. Larrea, V. M. M. Sebastian, and M. Arruebo. 2016. “Continuous Synthesis of Drug-Loaded Nanoparticles Using Microchannel Emulsifcation and Numerical Modeling: Effect of Passive Mixing.” International Journal of Nanomedicine 11: 3397–416.10.2147/IJN.S108812Suche in Google Scholar PubMed PubMed Central
Stankiewicz, A. I., and J. A. Moulijn. 2000. “Process Intensification: Transforming Chemical Engineering.” Chemical Engineering Progress 96(1): 22–33.Suche in Google Scholar
Su, Y., K. Kuijpers, V. Hessel, and T. Noël. 2016. “A Convenient Numbering-Up Strategy for the Scale-Up of Gas–Liquid Photoredox Catalysis in Flow.” Reaction Chemistry & Engineering 1: 73–81.10.1039/C5RE00021ASuche in Google Scholar
Suh, Y. K., and S. Kang. 2010. “A Review on Mixing in Microfluidics.” Micromachines 1: 82–111.10.3390/mi1030082Suche in Google Scholar
Sultan, M.A., C.P. Fonte, M.M. Dias, J.C.B. Lopes, and R.J. Santos. 2012. “Experimental Study of Flow Regime and Mixing in T-Jets Mixers.” Chemical Engineering Science 73: 388–99.10.1016/j.ces.2012.02.010Suche in Google Scholar
Sun, J., J. Ju, L. Zhang, and N. Xu. 2008. “Synthesis of Biodiesel in Capillary Microreactors.” Industry Engineering Chemistry Research 47: 1398–403.10.1021/ie070295qSuche in Google Scholar
Tabeling, P. 2005. Introduction to Microfluidics. Great Britain: Oxford University Press.Suche in Google Scholar
Tapanes, N. C. O., D. A. G. Aranda, J. W. De M. Carneiro, and A. C. A. Antunes. 2008. “Transesterification of Jatropha Curcas Oil Glycerides: Theoretical and Experimental Studies of Biodiesel Reaction.” Fuel 87: 2286–95.10.1016/j.fuel.2007.12.006Suche in Google Scholar
Togashi, S., T. Miyamoto, Y. Asano, and Y. Endo. 2009. “Yield Improvement of Chemical Reactions by Using a Microreactor and Development of a Pilot Plant Using the Numbering-Up of Microreactors.” Journal of Chemical Engineering of Japan 42: 512–19.10.1252/jcej.08we277Suche in Google Scholar
Wang, J., F. Li, and R. Lakerveld. 2018. “Process Intensification for Pharmaceutical Crystallization.” Chemical Engineering & Processing: Process Intensification 127: 111–26.10.1016/j.cep.2018.03.018Suche in Google Scholar
Wang, K., Y. Lu, and G. Luo. 2014. “Strategy for Scaling-Up of Microsieve Dispersion Reactor.” Chemical Engineering Technology 37: 2116–22.10.1002/ceat.201400296Suche in Google Scholar
Whitesides, G. M. 2006. “The Origins and the Future of Microfluidics.” Nature 442: 368–73.10.1038/nature05058Suche in Google Scholar PubMed
Xia, Y., and G. M. Whitesides. 1998. “Soft Lithography.” Annual Review of Materials Research 28: 153–84.Suche in Google Scholar
Yap, S. K., W. K. Wong, N. X. Yang Ng, and S. A Khan. 2017. “Three-Phase Microfluidic Reactor Networks – Design, Modeling and Application to Scale-Out Nanoparticle-Catalyzed Hydrogenations with Online Catalyst Recovery and Recycle.” Chemical Engineering Science 169: 117–27.10.1016/j.ces.2016.12.005Suche in Google Scholar
Zhang, J., K.Wang, A. R.Teixeira, K.F.Jensen, and G.Luo. 2017. “Design and Scaling up of Microchemical Systems: A Review.” Annual Review of Chemical and Biomolecular Engineering8: 13.1–13.21.10.1146/annurev-chembioeng-060816-101443Suche in Google Scholar PubMed
© 2018 Walter de Gruyter GmbH, Berlin/Boston
Artikel in diesem Heft
- review
- Application of Microfluidics in Process Intensification
- article
- A Versatile Converter of Liquid Hydrocarbons for the Production of Reducing and Carbonization Atmospheres
- Design of Impeller Blades for Intensification of Gas-Liquid Dispersion Process in a Stirred Tank
- Experimental Study of the Mixing and Segregation Behavior in Binary Particle Fluidized Bed with Wide Size Distributions
- Studies of Dehydrogenation Reaction over Zinc-Alumina Catalyst
- Pressure-Leaching Behavior of Nickel from Ni–Mo Ore in Aqueous Oxygenated Media
- Impact of Chemical Reaction on MHD 3D Flow of a Nanofluid Containing Gyrotactic Microorganism in the Presence of Uniform Heat Source/Sink
- Impact of Dense Internals on Fluid Dynamic Parameters in Bubble Column
- Improvement of Quality and Digestibility of Moringa Oleifera Leaves Feed via Solid-State Fermentation by Aspergillus Niger
- Adsorption of Hexavalent Chromium by Eucalyptus camaldulensis bark/maghemite Nano Composite
Artikel in diesem Heft
- review
- Application of Microfluidics in Process Intensification
- article
- A Versatile Converter of Liquid Hydrocarbons for the Production of Reducing and Carbonization Atmospheres
- Design of Impeller Blades for Intensification of Gas-Liquid Dispersion Process in a Stirred Tank
- Experimental Study of the Mixing and Segregation Behavior in Binary Particle Fluidized Bed with Wide Size Distributions
- Studies of Dehydrogenation Reaction over Zinc-Alumina Catalyst
- Pressure-Leaching Behavior of Nickel from Ni–Mo Ore in Aqueous Oxygenated Media
- Impact of Chemical Reaction on MHD 3D Flow of a Nanofluid Containing Gyrotactic Microorganism in the Presence of Uniform Heat Source/Sink
- Impact of Dense Internals on Fluid Dynamic Parameters in Bubble Column
- Improvement of Quality and Digestibility of Moringa Oleifera Leaves Feed via Solid-State Fermentation by Aspergillus Niger
- Adsorption of Hexavalent Chromium by Eucalyptus camaldulensis bark/maghemite Nano Composite