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Modular continuous production concepts are already successfully applied in research, development, and piloting of a series of chemical compounds in the markets of fine chemistry and pharmaceutical products. Besides, first case studies for the application of those concepts in industrial scale are reported. Current European research projects focus to proof their applicability in a broader range. The elaborated know-how will be commercially used in a franchise between BTS, INVITE, Ehrfeld Mikrotechik BTS, and further partners in the product Flo-namic®. One core element of these production concepts are micro-and millistructured devices assisting continuous-flow processes due to their superior transport characteristics and small holdup. In small-scale production concepts, these special devices have to be considered together with conventional technology. The platform concept developed by TU Dortmund University for chemical manufacturing simplifies the scale-up process from lab to container scale and beyond on different levels in flow rate, temperature, or other process conditions.

The fluidized‐bed chemical vapor deposition (CVD) process for polycrystalline silicon production is considered to be the most attractive alternative to the conventional bell‐jar process. In order to obtain stable operation, high space‐time‐yields and high purity of the product several obstacles have to be eliminated. Reaction conditions must be optimized to avoid the homogeneous decomposition of silane and minimize silicon dust formation. The effect of temperature, silane partial pressure, gas velocity and the size of bed particles has to be identified. These dependencies and the interaction between hydrodynamics and kinetics of homogeneous and heterogeneous CVD‐reactions were studied in a laboratory‐scale fluidized‐bed reactor.

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Bayer Technology Services offers fully-integrated solutions along the life cycle of chemical/pharmaceutical plants -from development, through engineering and construction, to process optimization for existing plants. The Bayer subsidiary employs 2700 people worldwide at its headquarters in Leverkusen and other German locations, as well as in regional offices in Belgium, Brazil, India, Mexico, the People ' s Republic of China, Russia, Singapore, the United Arab Emirates and the United States. Additional information about Bayer Technology Services is available at www.bayertechnology.com.If higher efficiency and safety in the production of fine and specialty chemicals or active ingredients is to be strived for, flow chemistry could be the solution. Continuous flow processing is regarded as the key element for intensifying processes. Reaction conditions like temperature, mixing and stoichiometry can be controlled precisely, even locally, enabling an attractive yield improvement, reduction of energy consumption and shortening of process time. Furthermore, critical reactions using hazardous reactants, as well as very fast reactions, can run safely due to the perfect control capabilities of the flow chemistry approach.Based on the experience of many process examples, Flonamic of Bayer Technology Services offers flow chemistry solutions. This product comprises service offerings which cover the entire development process -from the assessment of the initial idea, up to implementation in production. A key element of this approach is the application of the modular principle -during the development phase and finally for the realization of container based production units assembled from standardized modules for each process step. The development processRegardless of the starting point, be it the task to convert an existing batch process to continuous production, or the implementation of an entirely new continuous process, the Flonamic development process usually starts at a small scale in the laboratory. This first step comprises a systematic combination of chemical characterizations, including kinetic data, computational simulations and laboratory optimization trials using micro and milli process technologies (Figure 1). Based on respective modular micro or milli reaction devices, these technologies are applied to develop processes on a small scale, enabling a fast optimization of process steps like mixing, dispersing, reaction, extracting and others.Already during this stage, the major benefits of flow chemistry are applied, like optimum control of mass and heat transfer for very fast and very exothermic or endothermic reactions, maximization yields of intermediates in consecutive reactions, opening novel process windows, e.g., by using supercritical fluids and enabling the safe handling of critical reactions due to small holdup and the best control of mixing and temperature.The results of these optimizations could be, for instance, increased selectivity for individual process steps Brought to you by |