Design, Fundamental Principles of Fabrication and Applications of Microreactors

This study highlights the development of small-scale reactors, in the form of microstructures with microchannel networking. Microreactors have achieved an impressive reputation, regarding chemical synthesis ability and their applications in the engineering, pharmaceutical, and biological fields. This review elaborates on the fabrication, construction, and schematic fundamentals in the design of the microreactors and microchannels. The materials used in the fabrication or construction of the microreactors include silicon, polymer, and glass. A general review of the application of microreactors in medical, biological, and engineering fields is carried out and significant improvements in these areas are reported. Finally, we highlight the flow patterns, mixing, and scaling-up of multiphase microreactor developments, with emphasis on the more significant industrial applications.

Stable amorphous cobalt nanoparticles formed by an in situ rapidly cooling microfluidic process

The controlled synthesis of nanoparticles (NPs) with stable crystal structures and stable physical and chemical properties is a key issue for commercial applications. The use of a microfluidic reactor (MR) process has proven to be a flexible approach to control the fine crystal structures and the magnetic properties during the ripening and aging of the NPs. We have developed an in situ rapidly cooling microfluidic process (IRCMP) in which Co NPs with stable crystal structures and magnetic properties are synthesized by using elevated reaction temperatures followed by rapid quenching of the colloids to reduced temperatures. The Co NPs that are obtained by this process demonstrate stable crystal structures and stable magnetic properties for a much longer period of time (at least 3 months) than for Co NPs obtained by performing the reaction and the quenching processes at room temperature or under sonication.

Electrokinetically driven fluidic transport in integrated three-dimensional microfluidic devices incorporating gold-coated nanocapillary array membranes

Electrokinetically driven fluid transport was evaluated within three-dimensional hybrid nanofluidic-microfluidic devices incorporating Au-coated nanocapillary array membranes (NCAMs). Gold NCAMs, prepared by electroless gold deposition on polymeric track-etched membranes, were susceptible to gas bubble formation if the interfacial potential difference exceeded approximately 2 V along the length of the gold region. Gold membranes were etched to yield 250 microm wide coated regions that overlap the intersection of two orthogonal microfluidic channels in order to minimize gas evolution. The kinetics of electrolysis of water at the opposing ends of the gold region was modeled and found to be in satisfactory agreement with experimental measurements of the onset of gas bubble formation. Conditions to achieve electrokinetic injection across Au-coated NCAMs were identified, with significant reproducible injections being possible for NCAMs modified with this relatively thin gold stripe. Continuous gold films led to suppressed injections and to a variety of ion enrichment/depletion effects in the microfluidic source channel. The suppression of injections was understood through finite element modeling which revealed the presence of a significant electrophoretic velocity component in opposition to electroosmotic flow at the edge of the Au-dielectric regions.

Measurement of electroosmotic flow in capillary and microchip electrophoresis

Microfluidics is the science and technology of systems that process or manipulate small amounts of fluids, using channels with dimensions of tens of micrometers. Electroosmotic flow (EOF) is an important characteristic of fluids in microchannels. In this paper, EOF generation, effects on separation and definition of EOF are introduced. And EOF measurement methods on capillary electrophoresis (CE) and microchip CE are systematically reviewed based on detection principle, hallmarks of EOF measurement methods are presented, the devices and signals are also schematically described. This paper offers researchers a guidance to obtain an estimate of EOF mobility in capillary and microchip electrophoresis.

Microreactors as tools in the hands of synthetic chemists

Recent developments in the construction of microstructured reaction devices and their wide-ranging applications in many different areas of chemistry suggest that microreactors may significantly impact the way chemists conduct experiments. Miniaturizing reactions offers many advantages for the synthetic organic chemist: high-throughput scanning of reaction conditions, precise control of reaction variables, the use of small quantities of reagents, increased safety parameters, and ready scale-up of synthetic procedures. A wide range of single and multiphase reactions has been performed in microfluidic-based devices. Certainly, microreactors cannot be applied to all chemistries yet and microfluidic systems also have disadvantages. Limited reaction time ranges, high sensitivity to precipitating products, and analytical challenges have to be overcome. An overview of microfluidic devices available for chemical synthesis is provided and some specific examples, mainly from our laboratory, are discussed to illustrate the potential of microreactors.

Microreactors as Tools for Synthetic Chemists—The Chemists' Round-Bottomed Flask of the 21st Century?

Will microreactors replace the round-bottomed flask to perform chemical reactions in the near future? Recent developments in the construction of microstructured reaction devices and their wide-ranging applications in many different areas of chemistry suggest that they can have a significant impact on the way chemists conduct their experiments. Miniaturizing reactions offers many advantages for the synthetic organic chemist: high-throughput scanning of reaction conditions, precise control of reaction variables, the use of small quantities of reagents, increased safety parameters, and ready scale-up of synthetic procedures. A wide range of single- and multiphase reactions have now been performed in microfluidic-based devices. Certainly, microreactors cannot be applied to all chemistries yet and microfluidic systems also have disadvantages. Limited reaction-time range, high sensitivity to precipitating products, and new physical, chemical, and analytical challenges have to be overcome. This concept article presents an overview of microfluidic devices available for chemical synthesis and evaluates the potential of microreactor technology in organic synthesis.

Miniaturized continuous flow reaction vessels: influence on chemical reactions

This review offers an overview of the relatively young research area of continuous flow lab-on-a-chip for synthetic applications. A short introduction on the basic aspects of lab-on-a-chip is given in the first part. Subsequently, the effects of downscaling reaction vessels as well as the advantages of the continuous flow microfluidic approach over conventional chemical laboratory batch methodologies are illustrated by a number of examples of organic reactions carried out in microfluidic devices. The last part deals with a key issue of the lab-on-a-chip approach, viz. the integration of the microreactor with the analytical instrumentation to achieve high-throughput reaction monitoring.

Water in micro- and nanofluidics systems described using the water potential

This Tutorial Review shows the behaviour of water in micro- and nanofluidic systems. The chemical potential of water ('water potential') conveniently describes the energy level of the water at different locations in and around the system, both in the liquid and gaseous state. Since water moves from high to low potential, the water potential enables us to predict and describe the direction of water movement inside systems and between systems and their surroundings. Practical examples of microfluidic devices illustrate the different contributions to the water potential (capillary, gravitational, entropic (osmotic) in liquid water; the partial vapour pressure in atmospheric water and van der Waals forces in water films) and the resulting water movement.

Modelling and optimisation of enzymatic separating micro-reactor

A mathematical model of an enzymatic separating microreactor with the electro-osmotic control of reaction component transport rates is analysed. The micro-reactor is considered in a form of a thin channel filled with a gel containing an immobilised enzyme and an adsorbent where the enzyme reaction, the molecular diffusion, the electro-osmotic flux and the adsorption take place. The substrate inhibited enzyme reaction splitting a non-ionic substrate to two non-ionic products is considered. The reactor operates in a periodic regime, when the channel entry is exposed to the periodic substrate concentration pulses. A chromatographic separation of reaction components, therefore, proceeds in the channel. Effects of principal operational parameters of the reactor system-the reaction channel length, the electric current density, the substrate inlet concentration, the rate of adsorption, and the enzyme activity--on resolution of the products at reactor outlet are analysed. The existence of optimum parameter values (maximising the resolution of reaction products) is shown and a multiparametric optimisation of the reactor performance is accomplished.

Microchannel protein separation by electric field gradient focusing

A microchannel device is presented which separates and focuses charged proteins based on electric field gradient focusing. Separation is achieved by setting a constant electroosmotic flow velocity against step changes in electrophoretic velocity. Where these two velocities are balanced for a given analyte, the analyte focuses at that point because it is driven to it from all points within the channel. We demonstrate the separation and focusing of a binary mixture of bovine serum albumin and phycoerythrin. The device is constructed of intersecting microchannels in poly(dimethylsiloxane)(PDMS) inlaid with hollow dialysis fibers. The device uses no exotic chemicals such as antibodies or synthetic ampholytes, but operates instead by purely physical means involving the independent manipulation of electrophoretic and electroosmotic velocities. One important difference between this apparatus and most other devices designed for field-gradient focusing is the injection of current at discrete intersections in the channel rather than continuously along the length of a membrane-bound separation channel.

The application of micro reactors for organic synthesis

This tutorial review describes how micro reactors are being applied to synthetic chemistry covering a wide range of applications, from the preparation of nanograms of material for drug discovery and screening to the multi-tonne production of fine chemicals. This article explores how miniaturisation may revolutionise chemical synthesis and demonstrates that products are generated in higher yield and purity compared to the equivalent bulk reactions, in much shorter periods of time.

Low-dispersion electrokinetic flows for expanded separation channels in microfluidic systems:

A novel methodology to design on-chip conduction channels is presented for expansion of low-dispersion separation channels. Designs are examined using two-dimensional numerical solutions of the Laplace equation with a Monte Carlo technique to model diffusion. The design technique relies on trigonometric relations that apply for ideal electrokinetic flows. Flows are rotated and stretched along the abrupt interface between adjacent regions having differing specific permeability. Multiple interfaces can be placed in series along a channel. The resulting channels can be expanded to extreme widths while minimizing dispersion of injected analyte bands. These channels can provide a long path length for line-of-sight optical absorption measurements. Expanded sections can be reduced to enable point detection at the exit section of the channel. Designed to be shallow, these channels have extreme aspect ratios in the wide section, greatly increasing the surface-to-volume ratio to increase heat removal and decrease unwanted pressure-driven flow. The use of multiple interfaces is demonstrated by considering several three-interface designs. Faceted flow splitters can be constructed to divide channels into any number of exit channels while minimizing dispersion. The resulting manifolds can be used to construct medians for structural support in wide, shallow channels.

Multienzyme catalysis in microfluidic biochips

The attachment of enzymes to glass microfluidic channels has been achieved using a highly reactive poly(maleic anhydride-alt-alpha-olefin) (PMA)-based coating that is supplied to the microchannel in a toluene solution. The PMA reacts with 3-aminopropyltriethoxysilane groups linked to the glass surface to form a matrix that enables additional maleic anhydride groups to react with free amino groups on enzymes to give a mixed covalent-noncovalent immobilization support. Using a simple T-channel microfluidic design, with reaction channel dimensions of 200 microm wide (at the center), 15 microm deep, and 30 mm long giving a reaction volume of 90 nL, soybean peroxidase (SBP) was attached at an amount up to 0.6 microg/channel. SBP-catalyzed oxidation of p-cresol was performed in aqueous buffer (with 20% [v/v], dimethylformamide) containing H(2)O(2), with microfluidic transport enabled by electroosmotic flow (EOF). Michaelis-Menten kinetics were obtained with K(m) and V(max) values of 0.98 mM and 0.21 micromol H(2)O(2) converted/mg SBP per minute, respectively. These values are nearly identical to nonimmobilized SBP kinetics in aqueous-DMF solutions in 20-microL volumes in 384-well plates and 5-mL reaction volumes in 20-mL scintillation vials. These results indicate that SBP displays intrinsically native activity even in the immobilized form at the microscale, and further attests to the mild immobilization conditions afforded by PMA. Bienzymic and trienzymic reactions were also performed in the microfluidic biochip. Specifically, a combined Candida antarctica lipase B-SBP bienzymic system was used to convert tolyl acetate into poly(p-cresol), and an invertase-glucose oxidase SBP trienzymic system was used to take sucrose and generate H(2)O(2) for SBP-catalyzed synthesis of poly(p-cresol).

Microfluidic peroxidase biochip for polyphenol synthesis

An enzyme-containing microfluidic biochip has been developed for the oxidative polymerization of phenols. The biochip consists of a simple T-junction with two feed reservoirs 20 mm apart and a microreaction channel 30 mm long. The channel is 15 microm deep and 200 microm wide at the center, giving a reaction volume of 90 nL. The biochip was fabricated using conventional photolithographic methods on a glass substrate etched using a HF-based solution. Fluid transport was enabled using electroosmotic flow. Soybean peroxidase was used as the phenol oxidizing catalyst, and in the presence of p-cresol and H(2)O(2), essentially complete conversion of the H(2)O(2) (the limiting substrate) occurred in the microchannel at a flow rate of ca. 290 nL/min. Thus, peroxidase was found to be intrinsically active even upon dramatic scale-down as achieved in microfluidic reactors. These results were extended to a series of phenols, thereby demonstrating that the microfluidic peroxidase reactor may have application in high-throughput screening of phenolic polymerization reactions for use in phenolic resin synthesis. Finally, rapid growth of poly(p-cresol) on the walls of the microreaction channel could be performed in the presence of higher H(2)O(2) concentrations. This finding suggests that solution-phase peroxidase catalysis can be used in the controlled deposition of polymers on the walls of microreactors.

Immobilized oxazoline-containing ligands in asymmetric catalysis--a review

Metal complexes of chiral oxazoline derivatives immobilized on soluble as well as insoluble supports serve as versatile asymmetric catalysts in a variety of applications. In a few cases recovery and reuse of the chiral ligands have been achieved.

1,4-addition of enolates to alpha,beta-unsaturated ketones within a micro reactor

We demonstrate the formation of a series of diketone enolates and their subsequent reaction with alpha,beta-unsaturated carbonyl compounds in order to prepare a variety of Michael adducts. In all cases, the conversions observed within a micro reactor were greater than those obtained in batch.

Microfabricated devices in biotechnology and biochemical processing

In the past few years, interdisciplinary science and technologies have converged to create exciting challenges and opportunities, which involve a new generation of integrated microfabricated devices. These new devices are referred to as 'lab-on-a-chip' or Micro Total Analysis Systems. Their development involves both established and evolving technologies, which include microlithography, micromachining, Micro Electro Mechanical Systems technology, microfluidics and nanotechnology. This review summarizes the key device subject areas and the basic interdisciplinary technologies, and gives a better understanding of how these technologies can be used to provide appropriate technical solutions to fundamental problems. Important applications for this novel 'synergized' technology in chemical and biotechnological processing, in addition to the application of simulation methods in the development of microfabricated devices, will also be discussed.

Quantitative 3-dimensional profiling of channel networks within transparent lab-on-a-chip microreactors using a digital imaging method

We have developed a method for the quantitative 3-dimensional profiling of micron sized channel networks within optically transparent "lab-on-a-chip" microreactor devices. The method involves capturing digitised microscope images of the channel network filled with an optically absorbing dye. The microscope is operated in transmission mode using light filtered through a narrow bandpass filter with a maximum transmission wavelength matching the wavelength of the absorbance maximum of the dye solution. Digitised images of a chip filled with solvent and dye solution are analysed pixel by pixel to yield a spatially resolved array of absorbance values. This array is then converted to optical path length values using the Beer-Lambert law, thereby providing the 3D profile of the channel network. The method is capable of measuring channel depths from 10 to 500 microm (and probably even smaller depths) with an accuracy of a few percent. Lateral spatial resolution of less than 1 microm is achievable. It has been established that distortion of the measured profiles resulting from a mismatch in refractive index between the dye solution and the glass of the microreactors is insignificant. The method has been successfully used here to investigate the effects of thermal bonding and etch time on channel profiles. The technique provides a convenient, accurate and non-destructive method required to determine channel profiles; information which is essential to enable optimisation of the operating characteristics of microreactor devices for particular applications.