Rapid Mixing Reactor for Biphasic Reaction Scale-up
Abstract
This application note describes:
- Vapourtec Reactors for Rapid Mixing and High Flow rate pump module
- Greater than 99.9% conversion at a 58 s residence time in a 60 ml reactor
- Over 4.5 kg/day production with just the footprint of a Vapourtec R-Series
One example of a reaction with a challenging mixing behaviour is an ester synthesis via a Steven’s oxidation, which uses aqueous sodium hypochlorite to oxidise an aldehyde to an ester in the presence of an alcohol, allowing the direct synthesis of the ester from the aldehyde. The aldehyde is insoluble in the aqueous mix, and so is in an organic solvent, which results in a biphasic reaction solution. To facilitate the reaction, a phase-transfer catalyst is employed to shuttle the reactants between phases, Figure 1.
Background
The scale-up of a successful reaction is an important stage in process development, and one that is ideally suited to continuous flow chemistry. Achieving a high throughput of material, with high output of the desired product is very dependent on reaction kinetics; the faster the reaction, the more product can be produced in a certain time. Good mixing is critical to ensuring the reaction proceeds as fast as possible, and is an important feature of reaction scale-up. The Vapourtec large diameter PFA Reactors for Rapid Mixing contain static mixers throughout their length to increase a much more dynamic mixing environment than a standard tubular reactor, and are ideal for high throughput applications.
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