Micro reaction Technology – for miniaturization of chemical reaction systems

In recent times chemical compounds need greater speed in the discovery process, which requires advanced automation. But majority of the current reactions are still performed by applying conventional techniques and apparatus. This has led to severe impact on the scale-up process. With recent advances in chemical reaction technology, sub-millimetre/sub-millilitre sized micro structured reactors, mixers and other micro process components have been developed. One of these technologies leading to miniaturization of reaction systems is the ‘Micro reaction technology (MRT)’ and these reactors are named as ‘Micro reactors.’ Micro reactors gained more importance in the field of chemistry, molecular biology and pharmaceutical chemistry etc by producing products in larger volumes. In this context, the present article will explain various concepts involved in the design, manufacturing and applications of micro reactors.

Introduction

MRT is a concept, which can increase performance of reactions in a continuous manner, within well-defined reaction channels, where typical dimensions are of the order <1000 μm and volumes. MRT which is growing in its usage is not a new concept, but has been suggested in the early eighties.

Main features of MRT are that the reaction conditions can be transferred from laboratory-scale reactors to production sites without the need for reoptimization of various conditions. MRT has certain advantages.

• Optimal mixing
• Effective heat exchange
• Small reaction volume
• Faster product development
• Reduced exposure to hazardous chemicals

Efficient Heat Transfer

Micro reactors with their small surface to volume ratios are able to absorb heat created from a reaction much more efficiently than any batch reactor. In a micro reactor, the heat created by mixing the two reagents is also detectable. The small inner volume of a micro reactor (typically less than a millilitre) combined with its strong heat exchange efficiency guarantees the safe and stable performance of highly exothermic reactions over hours. Even explosive reactants and intermediates can be handled safely in a micro reactor.

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