Pharmaceutical Precipitation Reactor With Rotating Stator Rotor Assembly
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Solution Overview
Problem
Existing precipitation processes for producing pharmaceutical particles are challenged by extremely fast reaction times and the resulting non-Newtonian fluid, which causes clogging in mixing apparatuses, limiting the ability to perform continuous processes.
Innovation Solution
A reactor system with a stator and rotor assembly that supplies reactant materials through specific inlets, increasing the speed and reducing the first reactant material to small droplets before reaction, preventing clogging and enabling continuous precipitation of particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mixing apparatus (impinging jet mixers, high pressure homogenizers, static mixing) are used for precipitation process, then particle formation can occur, but the non-Newtonian fluid causes particles to stick to the wall of the precipitation device when velocity gradients are small, resulting in clogging of the mixing apparatus
Solution Approach 1:
The patent employs a dynamic mixing system with rotating elements that create high velocity gradients throughout the precipitation chamber. The rotational motion ensures continuous variation in flow patterns and velocity distributions, preventing particles from adhering to stationary surfaces and eliminating clogging while maintaining effective particle formation
Solution Approach 2:
The invention replaces conventional mechanical mixing apparatus with a fluid dynamic-based precipitation system. Instead of relying on mechanical impinging jets or homogenizers that create stagnant zones, the system uses controlled fluid flow and velocity gradients to achieve both particle formation and prevent wall adhesion through hydrodynamic forces
2Manufacturing precision
If precipitation reactions occur extremely fast with half-time of 0.5 second, then small particles can be produced, but the resulting non-Newtonian fluid causes clogging in continuous processes
Solution Approach 1:
The patent designs a continuous precipitation system where reactants are continuously fed into the precipitation chamber, mixing occurs continuously through rotational elements, and product is continuously removed. This continuous operation maintains constant velocity gradients and prevents the buildup of non-Newtonian fluid that would cause clogging, enabling sustained high-speed precipitation without interruption
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
The reactor system effectively produces uniform pharmaceutical particles without clogging, allowing for continuous operation and precise control over particle size and distribution, suitable for pulmonary delivery applications.
Implementation Method 1
The first reactant material is increased in speed and is reduced to small droplets
Implementation Method 2
the first and second reactant materials react to produce precipitation of particles in the reaction chamber
Data Source
AI summary
Reactors, reactor systems and methods for producing particles in a precipitation process are provided. The reactor includes a housing defining a reaction chamber, a stator assembly including two or more stators, a rotor assembly including two or more rotors, the rotor assembly configured for rotation about an axis of rotation relative to the stator assembly, a first inlet to supply a first reactant material to the reaction chamber at a first radial location, a second inlet to supply a second reactant material to the reaction chamber at a second radial location different from the first radial location, wherein the first and second reactant materials react to produce precipitation of particles in the reaction chamber, and an outlet to supply the particles formed in the reaction chamber.