CONTINUOUS FLOW REACTORS (1).pptx

continuous flow reactor, batch reactor, green chemistry, application , flow reactor, type of flow reactor , synthetic applications

1. FLOW CHEMISTRY  CONTINUOUS FLOW REACTORS  SUBMITTED BY:   UPASANA SHARMA   M.PHARMA (PHARMACEUTICAL CHEMISTRY) SUBMITTED TO:   Dr. RAJNISH KUMAR (PROFESSOR) NOIDA  INSTITUTE OF ENGINEERING AND TECHNOLOGY (PHARMACY INSTITUTE) GREATER NOIDA 

2. CONTENT: REACTORS FLOW CHEMISTRY PRINCIPLE WORKING PRINCIPLE BATCH AND FLOW REACTORS   TYPES OF FLOW REACTON ADVANTAGES SYNTHETIC APPLICATION CONCLUSON  REFRENCES 

3. REACTORS : REACTORS : RREACTORS : A reactor is a vessel or system in which a chemical reaction takes place. Example:   Batch reactors Continuous flow reactors  Continuous stirred tank reactor  Plug flow reactors  Fixed bed reactors  Fluidized bed reactors The choice of reactor type depends on various factors,  including the type of reaction, the reaction rate, the required product yield, and the required reaction conditions.

4. FLOW CHEMISTRY : It discover the early 20th century, with the development of continuous-flow processes in the chemical industry. Professor Steven Ley,   with his research group at the  University of Cambridge , began exploring the use of  microreactors and other flow technologies in the late 1990s .Another one The Professor Klavs Jensen, with his research group at the Massachusetts Institute of Technology (MIT) , developed a range of microreactors and flow technologies for chemical synthesis.  Jensen's work paved the way for the commercialization of flow chemistry systems and led to the establishment of several companies, including   Syrris  Ltd. and  Vapourtec  Ltd .Flow chemistry, also known as continuous-flow chemistry or microreactor technology, is a type of chemical synthesis that involves the use of continuous-flow reactors instead of traditional batch reactors.

5. PRINCIPLE:  REACTANT MIXTURE AT CONSTANT RATE ,AID OF PUMP AND OTHER MEANS OF FLOW CONTROL (PISTON PUMP, SYRINGE PUMP) TUBES AND SERIES OF TUBES (TUBULAR REACTOR,PLUG FLOW REACTOR) REACTOR (ALLOW TO REACT)  PRODUCT MIXTURE COLLECTED AT OUTLET 

6. WORKING PRINCIPLE:   1.Feeding of reactant:    Constant flow rate maintain constant concentration of reactant with the reactor  2.Mixing of reactant: to get homogeneous mixture degree of mixing is controlled  3.Reaction: reactant mixed.  reaction occur ,rate reaction controlled by factor- catalyst, temperature, pressure, concentration of reactant  4.Collection of product:   flow rate maintain, constant concentration of product  5.Monitoring and control:  optimal condition, temperature sensor, flow meter, pressure sensor , computer controlled feedback system

7. Pumps: used to deliver reproducible quantities of solvents and reagents; the usual types are piston, peristaltic, syringe or gear centrifugal pumps  Reaction loops: used to introduce small volumes of reagents T-piece: primary mixing point, where reagents streams are combined   Coil reactor: provides residence time for the reaction  Column reactor: packed with solid reagents, catalysts or scavengers   Back pressure regulator: controls the pressure of the system  Downstream unit: in-line analytics, work-up operations, etc

8. Scaling out -Run process longer, easiest method   Numbering –up - multi reactors in parallel used  Scaling-up: use of larger continuous reactor BATCH REACTOR  Stoichiometry -molar ratio of reagent Reaction time determined by vessels is stirred under fixed condition Reaction kinetics controlled by reagent exposure time under specified condition Flexibility more and initial product of new compound possible  Small quantity production  Reagent and concentration vary over product Time and mixing is important that affect kinetics of reaction  Mixing and mass transfer less and efficient  FLOW REACTOR  Stoichiometry- ratio of flow rate and molarity Reaction time and residence time (reactant in reactor zone)-  τ = V/q (V: volume of system and q: flow rate of system) Reaction kinetics  controlled by flow rate of reagent streams  Flexibility is less in continuous reaction and  modification of process is difficult  Large quantity production  Each portion specific concentration of starting material and product  Mixing and mass transfer is very efficient and effective  Control of temperature in flow process achieved accurately due to high surface area to volume ratio

9. Flow reactors types  : Plug flow reactors  Column reactors Gas reactors Reactors for slurries  Photochemical flow reactors  Trickle bed reactors   TYPES:  TYPE I – no catalyst  TYPE II- supported reagent  TYPE III- homogeneous catalyst  TYPE IV- supported catalyst 

10. ADVANTAGES :  I mproved Safety:   Better control over reaction conditions, reduces the likelihood of accidental exposure to hazardous materials. Higher Efficiency:  The continuous flow of reactants and products allows for better control over reaction parameters like temperature ,pressure, concentration of reactant and product, easier separation of the products. Scalability: Flow chemistry is easily scalable, meaning that a small reaction can be easily scaled up to a larger industrial-scale production. Faster Reactions: Flow chemistry can result in faster reaction times and more rapid product formation, which can save time and resources. Reduced Waste:   The efficient use of reagents and catalysts, fewer byproducts are produced, reducing waste and minimizing the need for purification steps. Improve product quality:  Purity, quality control and check by sensors ,maximum yield and minimum impurities. Broader Scope of Chemistry: Flow chemistry can be used for a wider range of chemical reactions than traditional batch reactions, including reactions that are difficult to perform or unstable under batch reaction conditions some reactive chemicals and hazardous chemicals  

11. SYNTHETIC APPLICATION: Continuous flow synthesis of Diphenhydramine HCl   Continuous flow synthesis of Ibuprofen  Continuous flow synthesis of Telmisartan

12. CONCLUSION:   A reactor is a   vessel or system   in which a chemical reaction takes place.  Flow chemistry, also known as continuous-flow chemistry or  microreactor technology,  is a type of chemical synthesis that involves the use of continuous-flow reactors instead of traditional batch reactors. Working: feeding, mixing, reaction, collection, monitoring and control follow reaction mechanism. Batch reactors and continuous flow reactors. Types  of reactors like plug flow and column reactor. Advantages  like improved control over production, enhance safety and product quality. Synthetic applications ,ibuprofen,telmisartan , diphenhydramine hydrochloride.

13. REFRENCES:   Wiles C, Watts P. Continuous flow reactors: a perspective. Green Chemistry. 2012;14(1):38-54. Wiles C, Watts P. Continuous flow reactors, a tool for the modern synthetic chemist. European journal of organic chemistry. 2008 Apr;2008(10):1655-71. Murata K, Hirano Y, Sakata Y, Uddin MA. Basic study on a continuous flow reactor for thermal degradation of polymers. Journal of Analytical and Applied Pyrolysis. 2002 Oct 1;65(1):71-90. Baumann M, Baxendale IR, Ley SV, Nikbin N, Smith CD, Tierney JP. A modular flow reactor for performing Curtius rearrangements as a continuous flow process. Organic & Biomolecular Chemistry. 2008;6(9):1577-86. Irfan M, Glasnov TN, Kappe CO. Heterogeneous catalytic hydrogenation reactions in continuous‐flow reactors. ChemSusChem . 2011 Mar 21;4(3):300-16.