This book provides chemists and engineers with the valuable information they need to evaluate the use of microreactors, by covering the technical, operational, and economic criteria for a decision on whether a microreactor is suitable for a given application. The book will explain the systems needed to use microreactors in production and it will provide scenarios of microreactor use in different chemistries, including implementation of this technology into larger scale production processes. Crucially, a chapter is devoted to guidelines on how to calculate costs for development, investment, and production with continuous flow microreactors.

THOMAS R. DIETRICH, PhD, is founder and Chief Executive Officer of mikroglas chemtech GmbH, a company producing chemical microreactors and microreaction equipment. In addition to being an author in several journals and a lecturer at conferences, Dr. Dietrich is a leading member of several international organizations, including the DECHEMA industry consortium MicroChemTec (Germany), the Process Development Division group on microchemical engineering within AIChE (USA), and the advisory board of the Centro de Microprocesos at the Tecnológico de Monterrey (Mexico).

Preface	p. xi
Contributors	p. xvii
Introduction	p. 1
Impact of Microtechnologies on Chemical Processing	p. 3
Innovation: An Answer to the Challenges of Sustainable Development	p. 3
Process Intensification: A New Paradigm in Chemical Engineering	p. 4
Microprocessing for Process Identification	p. 11
Intensified Flux of Information (R&D) vs. Intensified Flux of Material (Production)	p. 15
Implementation of Microtechnologies in Chemical Processing: A Few Select Examples	p. 16
Challenge of Cost Efficiency: Balance between Capex and Opex	p. 20
Perspectives	p. 24
Bibliography and Other Sources	p. 27
Microfluidic Methods	p. 29
Microreactors Constructed from Metallic Materials	p. 31
Metals as Materials of Construction for Microreactors	p. 31
Material Selection	p. 32
Micro- and Precision Engineering Methods	p. 37
Joining and Mounting Techniques	p. 44
Bibliography and Other Sources	p. 46
Microreactors Constructed from Insulating Materials and Semiconductors	p. 47
Silicon Microreactors	p. 47
Glass Microreactors	p. 55
Bibliography and Other Sources	p. 63
Micromixers	p. 65
Introduction	p. 65
Mixing Principles and Fluid Contacting	p. 66
Technical Aspects	p. 70
Evaluating the Performance of a Micromixer	p. 73
Multiphase Mixing	p. 79
Problems and Solutions	p. 82
Bibliography	p. 84
Microchannel Heat Exchangers and Reactors	p. 87
Microchannel Heat Exchangers	p. 87
Chemical Reaction and Microchannel Heat Exchangers	p. 126
Bibliography	p. 128
Separation Units	p. 131
Introduction	p. 131
Membrane Separation of Gases	p. 134
Absorption of Gases	p. 139
Stripping of Volatile Components	p. 145
Distillation of Binary Mixtures	p. 146
Immiscible Phase Liquid-Liquid Extraction	p. 146
Particle Separation from Liquids	p. 151
Concluding Remarks	p. 155
Bibliography	p. 156
Calculations and Simulations	p. 165
Introduction	p. 165
Mechanisms and Scales	p. 166
Modeling and Computation of Reacting Flows	p. 172
Evaluation and Validation of CFD Simulations	p. 179
Bibliography	p. 182
Peripheric Equipment	p. 185
Dosage Equipment	p. 187
Concept and Requirements	p. 187
Type of Pumps	p. 188
Range of Suitability	p. 194
Bibliography	p. 197
Micromachined Sensors for Microreactors	p. 199
Introduction	p. 199
Pressure Sensors	p. 201
Temperature Sensors	p. 215
Flow and Mass Flow Sensors	p. 220
Conductometric/Amperometric Sensors	p. 223
Optical Photometric and Fluorometric Sensors	p. 226
Closing Remarks	p. 237
Acknowledgments	p. 239
Bibliography and Other Sources	p. 239
Automating Microprocess Systems	p. 245
Automation: Why?	p. 245
Sensors and Actuators for Microprocess Systems	p. 247
Typical Architectures and Functionalities of Control Systems	p. 250
Examples of Automated Microprocess Systems	p. 262
Summary	p. 264
Bibliography	p. 264
Microreaction Plants	p. 265
Strategies for Lab-Scale Development	p. 267
Introduction	p. 267
Criteria for Choosing the Correct MRT Device	p. 269
Applications for MRT Plants	p. 275
Further Aspects of Lab-Scale Development	p. 279
Acknowledgments	p. 281
Bibliography	p. 281
Microreaction Systems for Education	p. 285
Introduction	p. 285
Influence of the Industrial Sector on Microreactor Education	p. 286
Academic Approaches to Teaching about Microreactors	p. 287
Academic Courses on Microreactors and Interdisciplinary Classes	p. 288
Future Outlook	p. 295
Bibliography	p. 295
Microreaction Systems for Large-Scale Production	p. 299
Overview of Large-Scale Opportunity and Challenges	p. 299
Scale-Up Considerations for Large-Scale Systems	p. 301
Competing with Conventional Technology and Economy of Scale	p. 310
Examples of Large-Scale Production	p. 312
Future of Large-Scale Production Opportunities	p. 320
Bibliography	p. 321
Process Intensification	p. 325
Introduction	p. 325
Definitions and Objectives	p. 325
International State-of-the-Art	p. 326
Guidelines	p. 328
Case Studies	p. 338
Other Intensification Principles	p. 345
Bibliography	p. 346
Standardization in Microprocess Engineering	p. 349
Introduction	p. 349
The MicroChemTec Standardization Initiative	p. 350
Conclusion and Outlook	p. 356
Bibliography	p. 357
Applications	p. 359
Polymerization in Microfluidic Reactors	p. 361
Introduction	p. 361
Polymerization in a Continuous Solution Flowing Through Microchannels	p. 362
Polymerization in Droplets	p. 364
Conclusions	p. 380
Bibliography	p. 380
Photoreactions	p. 385
Theory	p. 385
Photoreactions in Microreactors	p. 387
Typical Examples of Other Research	p. 397
Bibliography and Other Sources	p. 401
Intensification of Catalytic Process by Micro-Structured Reactors	p. 403
Introduction	p. 403
Characteristics of Microstructured Reactors	p. 405
Microstructured Reactors for Heterogeneous Catalytic Reactions	p. 412
Main Design Parameters of Catalytic MSR	p. 419
Conclusions	p. 425
Bibliography	p. 426
Microstructured Immobilized Enzyme Reactors for Biocatalysis	p. 431
Introduction	p. 431
Steps Toward a Microstructured Immobilized Enzyme Reactor	p. 435
Selected Examples from the Literature	p. 440
Acknowledgments	p. 441
Bibliography	p. 442
Multiphase Reactions	p. 449
Introduction	p. 449
Two-Phase Flow Regimes	p. 450
Examples of Microreactors Based on Segmented Flow	p. 453
Examples of Microreactors Based on Other Flow Types	p. 464
Concluding Remarks	p. 468
Bibliography	p. 469
Index	p. 475
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