Process microreactor materials

Microreactor technology has developed to such an extent that a wide variety of microreactor components, e.g. micropumps, mixers, reaction chambers, heat exchangers, separators and complete integrated microreaction systems with process control units have been fabricated using the appropriate microfabrication process and materials that are suitable for specific applications. 

Stainless steel is the material of choice for process chemistry. Consequently, stainless steel microreactors have been developed that include complete reactor process plants and modular systems. Reactor configurations have been tailored from a set of micromixers, heat exchangers, and tube reactors. The dimensions of these reactor systems are generally larger than those of glass and silicon reactors. These meso-scale reactors are primarily of interest for pilot-plant and fine-chemical applications, but are rather large for synthetic laboratories interested in reaction screening. The commercially available CYTOS Lab system (CPC 2007), offers reactor sizes with an internal volume of 1.1 ml and 0.1 ml, and modular microreactor systems (internal reactor volumes 0.5 ml to... 

W-Methyl-A/ -nitroso-p-toluenesulfonamide (MNTS) is an important precursor for the production of diazomethane. Diazomethane is then further converted to a range of useful molecules in the pharmaceutical and fine chemical industry [69]. Production of MNTS is a highly exothermic process and includes the presence of the extremely toxic materials. Stark et al. [70] have explored the application of microreactor technology for the production of this industrially valuable material, assuming that due to the efficient heat exchange and the closed system, microflow conditions provide a safer environment for these hazards. 

Some of the topics we discuss in this chapter are essential for understanding processes such as MEUF. The same ideas can also be used for other separation processes (e.g., protein separation in reverse micelles) and in genetic engineering, as mentioned in Vignette 1.3 in Chapter 1. We also see in this chapter other applications such as using micelles as microreactors, i.e., using the unique environment inside micelles for catalysis and material synthesis. 

Since it will take several years to realize such an integral software toolbox, individual approaches with separate steps have to be applied to meet gradually the requirements of microreactor design. Standard software for computational fluid dynamics is directly applicable in this context, and there are also powerful software tools for the simulation of special steps in microfabrication processes. However, there has been rather little experience with materials for microreactors, optimization of microreactor design, and, in particular, the treatment of interdependent effects. Consequently, a profound knowledge of the basic properties and phenomena of microreaction technology just described is absolutely essential for the successful design of microreaction devices. 

Penth, B., New non-dogging microreactor for chemical processing and nano materials, in Proceedings of the Micro.tec 2000, VDE World Microtechnologies Congress Expo 2000 (25-27 Sept. 2000), VDE Verlag, Berlin, 2000, 401-105. 

A negative photoresist, SU-8 (Microchem), was used in the microreactor mold process for preparing the PDSM-E microreactors. When exposed to ultraviolet light, material may be removed via a wet etching process leaving high-definition features in micrometer dimensions. Additionally, a microreactor has been constructed in silicon onto which layer-bylayer self-assembled polyelectrolytes and enzymes are deposited. This system is being used for comparison with the PDMS-E system performance. 

Microreactors (flow reactors with micrometer scale) were first employed in organic synthesis to perform chemical reactions in flow processes. The small dimensions of microreactors allow the use of minimal amounts of reagent under precisely controlled conditions, and the rapid screening of reaction conditions with improved overall safety of the process. To obtain synthetically useful amounts of material, either the microreactors are simply allowed to run for a longer period of time ( scale-out ), or several reactors are placed in parallel ( numbering up ) [29],... 

The glass and silicon materials can be subjected to every combination. To achieve structure sizes required for microreactors, the following processes are used ... 

Processes that work best with microreactors are fast and generate high-value materials. This restricts the use currently to such niches [62]. However, it is also more... 

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