Micro process technology opens new pathways for the development of economical, innovative and intensified processes. In the chemical and pharmaceutical industry, this technology plays an increasingly important role in research, development and production because of its decisive advantages over conventional technology. For example: microstructured devices have up to three orders of magnitude higher surface to volume ratio compared to conventional apparatuses. This results in intensified heat transfer. Microreactors are an excellent solution for extremely fast and highly exothermic or endothermic reactions. These reactions can be much better controlled in a microreactor and the possibility of hot spot for homogenous or heterogeneous reaction will be minimized. In conventional reactors strong temperature profiles could influence the product spectrum, and in some case even the catalyst can be irreversibly damaged. Microreaction technology therefore can be used to perform hard to control reactions, which otherwise cannot be performed in a conventional reactor.

Due to very high surface to volume ratio, the mass transfer limited processes can also take advantage of microtechnology. In micromixers the mixing velocity is an order of magnitude higher then in conventional mixers, which results in smaller mixing sections, a few millimeters or even less. Another advantage of micro devices is the option to control and adjust the process parameters much better. This leads not only to a better yield, but also to a higher level of safety. Additionally costs for downstream processing can be reduced significantly: for example by a solvent free production, production of reduced waste material during start up or shut down, change of product or potential production interference because of the small hold ups in continuous operating microreaction plants etc.

The Modular Microreaction System, which will be presented in this poster, has been demonstrated for liquid, gas-liquid and gas phase reactions and also for heterogeneous reactions. In addition to the Modular Microreaction System can also be used to produce micro- and nanoparticles. For example, modules, which were developed for precipitation reactions, can be used to produce pigments and catalysts. The advantages of suspension handling and the production of solid particles with specified properties lead to process innovations, which have already been installed in small production plants. Additionally some microreactors, allow the handling of slurries. The operating parameters include a temperature range of –20 to 200 °C; operating pressures up to 100 bar (at room temperature); and rated throughputs of up to 25 L/h for low-viscosity media. Special modules available significantly extend this process range. Among the items available are special reactors for reaction temperatures from –100 °C to 500 °C and stand-alone, high-performance production modules with rated throughputs of several thousand liter per hour.

With minimal effort, a whole lab or pilot plant can be installed with the Modular Microreaction Systems. In conjunction with process control system and peripheral equipments, these microreaction systems are powerful development and production tools, which allow innovations in all areas of the chemical industry. Sustained development of modules and new module materials will widen the field of application for the Modular Microreaction System. This will be shown in this poster.