Milli-Reactor Mixing for Organic Peroxide Safety
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Solution Overview
Problem
Current methods for producing organic peroxides face challenges such as uncontrollable decomposition, high safety risks, low yields, and increased costs due to the need for large quantities of reactive and potentially explosive reaction mixtures, which require extensive safety equipment and result in inefficient production processes.
Innovation Solution
The use of a static millimixer with multiple mixing structure levels and a heat exchanger in a millireactor system allows for precise temperature control and intensive mixing of reactants, preventing decomposition and enabling the production of larger quantities of organic peroxides with higher yields and improved safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stirred tank reactors are used with large quantities of reaction mixture, then the reaction can proceed, but safety risks increase and special safety equipment is required
Solution Approach 1:
The reaction mixture is segmented into small individual portions within a continuous flow system. The millireactor divides the total reaction volume into many small channel sections, each handling a tiny amount of reactive mixture at any given time, thereby maintaining safety while enabling continuous production of larger quantities
Solution Approach 2:
The invention uses a continuous flow hydraulic system where reactants are pumped through the millireactor channels. This fluid-based continuous processing replaces batch processing in large stirred tanks, allowing precise control of reaction conditions and continuous production without accumulating large quantities of reactive material
2Reliability
If large dilution is used to increase reaction reliability, then safety improves, but production costs increase and reaction speed decreases
Solution Approach 1:
The invention changes the key parameter from batch size to flow rate. By operating in continuous flow mode with optimized linear velocities through the millireactor channels, the system achieves both high reliability (through small reaction volumes) and high productivity (through continuous processing without batch interruptions). The residence time is precisely controlled by flow rate rather than batch volume
Solution Approach 2:
The system transitions from static batch processing to dynamic continuous flow processing. The continuous movement of reactants through the millireactor channels enables real-time control of reaction conditions, optimizing both safety and efficiency. The system can dynamically adjust flow rates to match production demands without requiring large dilution volumes
3Productivity
If two-phase reaction systems are used with conventional mixing, then the reaction can proceed, but mixing quality is insufficient and reaction rates are limited
Solution Approach 1:
The millireactor channels provide locally optimized flow conditions that enhance mixing at the micro-scale. The channel geometry and dimensions are specifically designed to create appropriate flow patterns (laminar or turbulent) that ensure thorough mixing of immiscible phases locally throughout the reactor volume, achieving homogeneous composition without excessive mixing intensity
Solution Approach 2:
The invention transitions from three-dimensional bulk mixing in stirred tanks to two-dimensional flow through planar channels. This dimensional change enables more effective mixing of immiscible phases by utilizing the channel geometry to create intimate contact between phases along the flow path, improving mass transfer and reaction rates
4Stability of the object's composition
If microreactors with small channels are used, then mixing improves, but particle deposition occurs and production of large amounts becomes difficult
Solution Approach 1:
The invention merges the advantages of microreactors (intense mixing) with the capacity for large-scale production by using a millireactor with larger channel dimensions. The channel sizes are optimized to prevent particle deposition while maintaining effective mixing, and multiple channels can be operated in parallel to achieve high production volumes without the limitations of microreactor geometry
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly enhances process safety, increases product yield, and reduces production costs by allowing for larger volumes of reactants to be processed without safety issues, while maintaining precise temperature control and efficient mixing, leading to improved reaction conversion and product quality.
Implementation Method 1
at least one heat exchanger, the channel widths of the millimixer being in the range of between >5 mm and 0,5 mm
Implementation Method 2
the process in at least a millireactor is carried out, the millireactor comprising at least one millimixer with at least two mixing structure levels
Data Source
AI summary
The invention relates to a method for efficiently and reliably producing organic peroxides, preferably dialkyl peroxides, peroxycarboxylic acids, peroxycarboxylic acid esters, diacyl peroxides, peroxycarbonate esters, peroxydicarbonates, ketone peroxides, and perketals, by means of at least one milli-mixer (2) and at least one heat exchanger (4), and a device (1) for performing the method.