Manufacturing in Flow: Controlled Multiphase Reactions on Demand (CoMRaDe)
Lead Research Organisation:
Loughborough University
Department Name: Chemical Engineering
Abstract
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Organisations
Publications
Loponov K
(2017)
Controlled multiphase oxidations for continuous manufacturing of fine chemicals
in Chemical Engineering Journal
| Description | For the first time membrane emulsification (the ability to generate an emulsion with a narrow drop size distribution at the size desired using a microporous membrane) has been coupled together with a plug flow reactor system. This enables continuous production of a material by: drop generation; reaction and mass transfer; separation of reaction products; and recycle of unreacted material for further reaction to take place. This has been applied, in the context of this grant, to oxidations of organic phases where the oxidant is in the aqueous phase. The unstable emulsion formed provides a means by which the drop size can be controlled to be small enough to provide high reaction surface area and, therefore, reaction rate whilst at the same time being large enough to facilitate the separation and recycle of the product and unreacted species. Control of drop size is critically important for the appropriate balance between these two conflicting requirements, and membrane emulsification provides the means by which this can be achieved. |
| Exploitation Route | Continuous processing based on liquid-liquid phase systems is commonly encountered in mass transfer and reaction engineering operations. We are currently investigating additional systems that have this at their core, e.g. complex coacervate production of encapsulated particulates, fluorine solvent based systems (with minimal solvent presence undergoing recycle), and similar biphasic systems. Thus, we are using the technique as an enabling technology that can be easily scaled-up to process capacity for a number of continuous processing requirements. A thesis on continuous complex coacervation, using the techniques developed, will be published in 2018 and a partnership on taking this forward commercially is being discussed further by one of the research team. |
| Sectors | Agriculture, Food and Drink,Chemicals,Healthcare,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology |
| Description | I now have several collaborations, and potential collaborations, on biphasic systems with mass transfer and with reaction. These include continuing work with Micropore Technologies Ltd, using their membrane emulsification systems, which we have been able to provide working information on. The work has also led to another EPSRC research proposal, currently under review, and using biphasic systems for catalytic reactions. The collaboration is with Chemists within my own institution. |
| First Year Of Impact | 2017 |
| Sector | Chemicals,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology |
| Impact Types | Economic |
| Description | ACHEMA Innovation Hall 9.2 stand E83 |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | ACHEMA is the world forum for chemical engineering and the process industry innovations platform and technology summit. We shared an exhibition stand with our EPSRC project collaborators, Imperial College, and were one of only three UK universities exhibiting in the Innovation Hall. We took demonstration equipment for both the oxidation (Imperial) and the membrane emulsification (Loughborough) technologies, and explained how they integrated together. We had well over 200 industrial delegates visit our stand and express an interest in our developing technology. Discussions with a number of these visitors are ongoing, and will be helpful for developing the technology further, to ensure maximum impact. |
| Year(s) Of Engagement Activity | 2015 |
| URL | http://www.achema.de/en/home.html |