Development of pilot-scale mini-fluidic technology for reacting systems involving immiscible fluids and solids

Mini-scale technology has been considered for a variety of applications in fuel cells, medical diagnostics, fine chemicals and pharmaceuticals. Suited to systems requiring rapid addition/removal of heat and reactions whose performance is dependent on the extent of mixing, mini-reactors have become increasingly common in single-phase applications. However, the introduction of multiple phases (Gas/Liquid, Liquid/Liquid, Liquid/Solid) complicates the reaction strategy, upstream distributor design, downstream separation and purification, process stability, and heat and mass transfer characteristics. Attempts in recent literature to address some of these challenges have primarily focused on improving contacting and performance for individual process components, often without consideration for the challenges involved in extending the technology to pilot-scale. As a result, efficient technology for peripheral equipment (i.e. distributors, valves, integrated micro-analytics for process control, downstream separation and purification) and the heuristics for their implementation are lacking. This deficiency has made a number of industries hesitant to pursue mini-fluidic technology. This research program involves multiple projects, each with individual benefits collectively contributing to the construction of modular pilot-plant technology for applications involving combinations of gas, liquid and/or solids. Initial projects explore fundamental design challenges in liquid-liquid and liquid-solid systems, focusing on the development of mini-scale oscillating flow reactors applied specifically for particle size control during crystallization/gelation and micro-encapsulation of high-value bio-materials. Concurrent development of mini-fluidic pilot-scale facilities for biofuels production via conventional and novel synthesis pathways will address challenges related to modular pilot-plant technology for multi-phase systems. Through the design of efficient distributors, mini-fluidic contactors, robust separation technology, control systems and solids-handling capabilities, this research will contribute to increased adoption of mini-fluidic technology across multiple industrial sectors.