Continuous-flow microreactor technology has been embraced by researchers in academia and industry due to its excellent transport properties and the increased safety and control over challenging chemical transformations. Despite its popularity, scaling the benefits associated with the microenvironment has proven to be a daunting challenge. This review provides an up-to-date overview concerning the different scale-up approaches of micro/milli-reactors, including numbering up (both internal and external), sizing up (increasing length, geometry similarity and constant pressure drop strategies) and a combination of numbering up and sizing up. The strategies, design principles and applications of each approach have been discussed in detail. Each scale-up approach has its merits and limitations. However, scale-up factors, that are required in the fine chemical and pharmaceutical industry, are within reach when different scale-up approaches are combined.

Scale-up of micro- and milli-reactors : An overview of strategies, design principles and applications

VOF-DEM study of solid distribution characteristics in slurry Taylor flow-based multiphase microreactors

Gas–liquid–solid “slurry Taylor” flow: Experimental evaluation through the catalytic hydrogenation of 3-methyl-1-pentyn-3-ol

Experimental study of gas-liquid-solid flow characteristics in slurry Taylor flow-based multiphase microreactors

External liquid solid mass transfer for solid particles transported in a milli-channel within a gas-liquid segmented flow

Multiphase hydrogenation using heterogeneous catalyst was conducted in a glass continuous flow reactor from Corning at the Centre for Process Innovation. The effect of temperature, hydrogen molar ratio, residence time, catalyst content and concentration were studied using noble-metal slurry catalyst. Efficient heat and mass transfer allow achieving full conversion with residence time lower than 1 minute and reduced catalyst load, while keeping selectivity in the same range as batch processes. These results show the high potential of Corning ® Advanced-Flow™ reactors for multiphase hydrogenations for high volume manufacturing.

Industry perspective - Custom synthesis Slurry hydrogenation in a continuous flow reactor for pharmaceutical application

Slurry hydrogenation in a continuous flow reactor for pharmaceutical application

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Industry perspective - Custom synthesis Slurry hydrogenation in a continuous flow reactor for pharmaceutical application

Slurry hydrogenation in a continuous flow reactor for pharmaceutical application