Analysis of Microstructured Reactor Characteristics for Process Miniaturization and Intensification

Performance, Efficiency, and Flexibility Analysis of a High-Temperature Proton Exchange Membrane Fuel Cell-Based Micro-Combined Heat-and-Power System with Intensification of the Steam Methane Reforming Step by Using a Millistructured Reactor

The complete simulation model of an existing 1 kW high-temperature proton exchange membrane (HT-PEM) fuel cell-based residential micro-combined heat-and-power process, including a compact intensified heat-exchanger-reactor, is developed in the simulation software ProSimPlus v3.6.16. Detailed simulation models of the heat-exchanger-reactor, a mathematical model of the HT-PEM fuel cell, and other components are presented. The results obtained by the simulation model and by the experimental micro-cogenerator are compared and discussed. To fully understand the behavior of the integrated system and assess its flexibility, a parametric study is performed considering fuel partialization and important operating parameters. The values of the air-to-fuel ratio = [30, 7.5] and steam-to-carbon ratio = 3.5 (corresponding to net electrical and thermal efficiencies of 21.5 and 71.4%) are chosen for the analysis of inlet/outlet component temperatures. Finally, the exchange network analysis of the full process proves that the process efficiencies can still be increased by further improving the process internal heat integration.

Demystifying the Flow: Biocatalytic Reaction Intensification in Microstructured Enzyme Reactors

Continuous (flow) reactors have drawn a wave of renewed interest in biocatalysis. Many studies find that the flow reactor offers enhanced conversion efficiency. What the reported reaction intensification actually consists in, however, often remains obscure. Here, a canonical microreactor design for heterogeneously catalyzed continuous biotransformations, featuring flow microchannels that contain the enzyme immobilized on their wall surface are examined. Glycosylations by sucrose phosphorylase are used to assess the potential for reaction intensification due to microscale effects. Key variables are identified, and their corresponding relationship equations, to describe, and optimize, the interplay between reaction characteristics, microchannel geometry and reactor operation. The maximum space-time-yield (STY_max) scales directly with the enzyme activity immobilized on the available wall surface. Timescale analysis, comparing the characteristic times of reaction (τ_reac ) and diffusion (τ_diff ) to the mean residence time (τ_res ), reveals operational conditions for optimum reactor output. Theoretical insight into determinants of microreactor performance is applied to biocatalytic syntheses of α-d-glucose 1-phosphate and α-glucosyl glycerol. Process boundaries for enzyme showing, respectively, high (80 U mg^-1 ) and low (4 U mg^-1 ) specific activities are thus established and options for process design revealed. Opportunities, and limitations, of the application of principles of microscale flow chemistry to biocatalytic transformations are made evident.

A. Enzymatic microreactors in biocatalysis: history, features, and future perspectives

Microfluidic reaction devices are a very promising technology for chemical and biochemical processes. In microreactors, the micro dimensions, coupled with a high surface area/volume ratio, permit rapid heat exchange and mass transfer, resulting in higher reaction yields and reaction rates than in conventional reactors. Moreover, the lower energy consumption and easier separation of products permit these systems to have a lower environmental impact compared to macroscale, conventional reactors. Due to these benefits, the use of microreactors is increasing in the biocatalysis field, both by using enzymes in solution and their immobilized counterparts. Following an introduction to the most common applications of microreactors in chemical processes, a broad overview will be given of the latest applications in biocatalytic processes performed in microreactors with free or immobilized enzymes. In particular, attention is given to the nature of the materials used as a support for the enzymes and the strategies employed for their immobilization. Mathematical and engineering aspects concerning fluid dynamics in microreactors were also taken into account as fundamental factors for the optimization of these systems.

Microscale technology and biocatalytic processes: opportunities and challenges for synthesis

Despite the expanding presence of microscale technology in chemical synthesis and energy production as well as in biomedical devices and analytical and diagnostic tools, its potential in biocatalytic processes for pharmaceutical and fine chemicals, as well as related industries, has not yet been fully exploited. The aim of this review is to shed light on the strategic advantages of this promising technology for the development and realization of biocatalytic processes and subsequent product recovery steps, demonstrated with examples from the literature. Constraints, opportunities, and the future outlook for the implementation of these key green engineering methods and the role of supporting tools such as mathematical models to establish sustainable production processes are discussed.

Recent advances in reactors for low-temperature Fischer-Tropsch synthesis: process intensification perspective

The low-temperature Fischer-Tropsch (LTFT) process aims to produce heavy cuts such as wax and diesel. For many years, there have been studies and improvements on the LTFT process to make the existing reactors more efficient. Recent studies have proposed innovative configurations such as monolithic loop and membrane reactors as well as microchannel reactor, which improved the performance of LTFT synthesis. This persuades us to update the existing knowledge about the available reactors. Some fundamental features of the current reactors, which belong to the classes of conventional reactors (fixed-bed reactors and slurry reactors) and innovative reactors, are discussed to assist the selection of the most efficient reactors specifically for heavy-cuts production. Published experimental and theoretical works with respect to developments in reactor technology and significant advances in catalysis (such as using structured packing, foams, and knitted wire as catalyst supports due to their excellent radial mixing properties) of the FT process are analyzed and discussed. Consequently, it is shown that the LTFT innovative reactors have higher CO conversions and selectivity of desired heavy cuts. Furthermore, the place of innovative reactors among conventional reactors in terms of effective process parameters on the product distribution has been estimated.