The fine chemicals and pharmaceutical industries are transforming how their products are manufactured, where economically favorable, from traditional batchwise processes to continuous flow. This evolution is impacting synthetic chemistry on all scales-from the laboratory to full production. This Review discusses the relative merits of batch and micro flow reactors for performing synthetic chemistry in the laboratory.

Deciding whether to go with the flow: evaluating the merits of flow reactors for synthesis.

Applications of microsystems (microreactors) in continuous-flow chemistry have expanded rapidly over the past two decades, with numerous reports of higher conversions and yields compared to conventional batch benchtop equipment. Synthesis applications are enhanced by chemical information gained from integrating microreactor components with sensors, actuators, and automated fluid handling. Moreover, miniaturized systems allow experiments on well-defined samples at conditions not easily accessed by conventional means, such as reactions at high pressure and temperatures. The wealth of synthesis information that could potentially be acquired through use of microreactors integrated with physical sensors and analytical chemistry techniques for online reaction monitoring has not yet been well explored. The increased efficiency resulting from use of continuous-flow microreactor platforms to automate reaction screening and optimization encourages a shift from current batchwise chemical reaction development to this new approach. We review advances in this new area and provide application examples of online monitoring and automation.

Integrated Microreactors for Reaction Automation: New Approaches to Reaction Development

Numerical and experimental studies of mixing characteristics in a T-junction microchannel using residence-time distribution

Axial dispersion in metal foams and streamwise-periodic porous media

Residence-time distribution as a measure of mixing in T-junction and multilaminated/elongational flow micromixers

A precise characterisation of microreactors can be achieved by determining the residence time distribution as one of the most important flow characteristics An approach specially designed for microreactor applications was developed, which employs a tracer ‘injection’ using the optical activation of a caged fluorescent dye Furthermore, the effect of the laminar flow on the determination of the residence time distribution in microreactors has been taken into account during the measurements and their interpretation to fulfill the requirements of the so-called ‘mixing-cup-problem’ on the microscale Residence time distributions for an intricately structured thin microreactor were determined for different velocities The ideality of the stimulus signal generated by the newly introduced technique is demonstrated for an analytically well-defined straight channel and compared with a signal derived from deconvolution of non-ideal input signals

A novel method for determining residence time distribution in intricately structured microreactors.

Characterization of full cone nozzles

Die Auslegung und Optimierung von Nasswaschern ausschlieslich anhand experimenteller Daten ist aufwendig. CFD-Werkzeuge zur Simulation von Nasswaschern konnen Experimente begleiten, um die Abscheideleistung der Apparate zu steigern und den Entwicklungsaufwand zu reduzieren. Es wird die Implementierung eines Modells zur Staubabscheidung bei Nasswaschern in der Simulationsumgebung ANSYS CFX vorgestellt. Basis der Implementierung ist die modellhafte Beschreibung der Reinigungswirkung von Einzeltropfen in einer staubbeladenen Gasatmosphare. Die berechneten spezifischen Reinigungsvolumina von Tropfen an einfachen Modellgeometrien zeigen eine gute Ubereinstimmung mit Literaturwerten.



The design and optimization of wet scrubbers solely based on laboratory experiments is a challenging task. In addition to laboratory experiments, CFD tools for wet scrubber simulation can improve the overall performance of wet scrubbers and reduce development efforts. Subroutines to map wet scrubbers into ANSYS CFX workbench are presented. The calculation of particle capture by individual water droplets is the major feature of the implementation. The simulated specific cleaning volumes of individual water droplets show a good agreement with values found in the literature within simple geometries.

CFD‐Simulation von Nasswäschern Teil 1. Grundlagen und Implementierung in ein kommerzielles CFD‐Programm

Die Herstellung von Formteilen und Dammstoffen aus modifizierten Polyurethanschaumen im Spruhverfahren hat in den letzten Jahren einen deutlichen Zuwachs erfahren. Hierbei werden Fullstoffe wie Glasfasern oder Metallpartikel in den Spruhstrahl eingebunden, um die gewunschten Produkteigenschaften zu erzielen. Die vorliegende Arbeit widmet sich der numerischen Simulation (CFD) der Spruhstrahlausbreitung unter besonderer Berucksichtigung der Einbindung von Partikeln in den Spruhstrahl. Experimentelle Untersuchungen an einer Spruhversuchsanlage zeigen, dass die hier vorgestellte Methode eine realitatsnahe Vorhersage der Partikeleinbindung in einen Spruhstrahl erlaubt.



Sound-absorbing mats consisting of cross-linked Polyurethane (PUR) foam and metal reinforcements, door panels and centre consoles for the interior of vehicles became important products for automotive component suppliers. The leading technology for the production of foam on the base of PUR with noise absorbing properties is the application of powder insertion (e.g. metal) in the PUR spray. The numerical simulation (CFD) of the spray including the particle-droplet interaction is presented. The theoretical background of the implemented models is explained and the experimental results achieved with a pilot plant are compared with the numerical results. The presented simulation offers the possibility to suitably predict the metal powder distribution in a PUR spray.

CFD-Simulation der Feststoffeinbindung in einen Sprühstrahl

Optimierung eines bestehenden Wäschers durch Simulation

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