Advanced Flow Reactors Teaming up Chemistry and Chemical Engineer Greener Processes and Improved Economics. Frank Schmidt Sales Director

Transcription

1 Advanced Flow Reactors Teaming up Chemistry and Chemical Engineer Greener Processes and Improved Economics Frank Schmidt Sales Director

2 Evolution (Revolution) in Chemical Processing 2

3 Cost Batch process scale up Manufacturing plant Pilot Plant Kilo Lab Lab scale Time 3

4 Process develoment benefits Example: Fine Chemicals and Pharma API production Batch Technology Discovery Development Production months, XX MM$ Distribution Laboratory Pilot Plant Scale up Technology transfer large scale production Key activity Early intermediate Advance RIsk on Intermediate the API Scale up failure manufacturing site Development of second generation process Transfer to manufacturing Regular production Limited scale up, management of numerous batch Complex transfer to regular production Final process parameter Laboratory Pilot Plant Scale up Technology definition transfer on large large scale scale production production 4

5 Fine and Pharma Industries Simple and fast PAR, Pilot Advanced Flow Reactor Technology 8-15 months, X MM$ Production Banks Laboratory Pilot Plant Scale up Technology transfer large scale production Key activities Development of second generation process Transfer to manufacturing Regular production One tool engineered to fit all needs Scale up failure, no scale up Risks at the manufacturing site Limited scale up, management of numerous batch Complex transfer to regular production no limitation no issues Final process parameter definition for large scale production simple 5

6 Fluidic modules: concept and library Heat exchange layer Reaction layer Heat exchange layer Heat transfer 700 microns Heat exchange fluid Reactants Mixing 300 microns 700 microns Pressure drop 1 millimeter 4 mm Reactants 6

7 The Impact of Dimensions ΔP L ηq = 128 π d Laminar flow Pressure drop Simple tube (bar) Heat transfer U x (S/V) (kw/m 3.K) Mixing Quality Villermaux (%) % bar μm 1 mm 1 cm 1 m 0,01 0, μm 6 mm 7

8 Corning Fluidic module heat exchange performance Apparatus Specific area, m 2 /m 3 Volumetric heat transfer coefficient (MW/m 3 K) Jacketed batch Batch with external heat exchanger Shell and tubes (metallic; water/water; 1 m/s) Plate (metallic, 4 mm spaced; water/water, 1 m/s) Corning glass fluidic modules (water/water, ~ 0.7 m/s) D. Lavric, Thermal performance of Corning glass microstructures, Proceedings of the Heat Transfer and Fluid Flow in Microscale III Conference, Hilton Whistler, BC, Canada, ECI international,

9 Fluidic modules: concept and library 9

10 AFR evaluation tool: flexible with capability all the way to pilot scale 10

11 Engineered reactor components Interfaces Frames Standard Fittings Connectors Tubing Sensing O-ring seals Fluidic Modules Labelling Add-on (insulation ) Instrumentation (Pressure relief valve ) 11

12 Glass Fluidic Modules are the building blocks 12

13 Numbering up: system distribution Individual feed of each reactor Mix system Passive distribution 13

14 Numbering up: system distribution 14

15 Scaling the technology to industrial production in 2 ways: Scale-out = increase the total fluidic channel path length/fluidic module Scale-up = increase the number of fluidic modules Scale-up: simple numbering up to full production Gen II scale-out Gen I Stacking scale-out Process Development and Pilot Production Capable Gen III scale-out 15

16 AFR: wide range of throughput (*) for production of Fine, Pharma and Specialty chemicals Gen I Gen II Gen III (Under development) T -60 C C P up to 18 bar g/min kg/h Tons / 5600h Tons / 8000h (*) per single reactor 16

17 Broad range of applications Reactions which have already benefited from Corning Advanced-Flow Reactor Alkylation Amidation Bromination Condensation Chlorination Metal Organic Hydrogenation Oxidation Nitration Sulfonation In mono or multi phase environments Miscible liquid feeds Non miscible feeds emulsions Liquid and gas feeds Suspensions 17

18 Case 1: Plant Footprint Comparison Batch vs. Continuous Selective Nitration NITRATION PLANT BATCH 400 ton/yr meter meter meter m m m meter m NITRATION PLANT CONTINUOUS 400 ton/yr 18

19 Case 1: Capex and Opex Comparison Batch vs. Continuous Selective Nitration NITRATION PLANT 400 tons/year Opex comparison batch versus continuous Batch Continuous Process Equipment Solvent recovery Storage Utilities Construction Wiring and automation Engineering Total Plant 19

20 Case 2: Plant Footprint Comparison Batch vs. Continuous Selective Hydrogenation HYDROGENATION PLANT 400 tons/year 20

21 Case 2: Capex and Opex Comparison Batch vs. Continuous Selective Hydrogenation HYDROGENATION PLANT 400 tons/year 21

22 Case 3: Plant Footprint Comparison Batch vs. Continuous Organo-Metallic Organo Metallic: 100 tons/year batch continuos 22

23 Case 3: Capex and Opex Comparison Batch vs. Continuous Organo-Metallic Organo Metallic: 100 tons/year 23

24 Advanced Flow Reactors: Greener and More Economical 24