Aqueous two‐phase extraction (ATPE) is increasingly considered to be a feasible unit operation, e.g., for the capture of monoclonal antibodies or recombinant proteins. So far, knowledge on the applicability of ATPE in antibody processes has been collected mostly in lab‐scale. In contrast, approaches for the integration of ATPE into a downstream process are investigated. A complete process sequence including extraction, washing, ultrafiltration, and ion‐exchange chromatography is discussed and suggested for antibody purification. Excellent antibody purities can be achieved. Additionally, a model is applied that allows early‐on prediction of a multistage ATPE with high prediction accuracy. Finally, an economic evaluation between ATPE and Protein A chromatography is performed, reaching up to five‐fold cost‐saving factors.

While devices based on micro effects are increasingly accepted in reaction engineering, there is still no breakthrough for separation applications like liquid‐liquid extraction (LLE). This situation results from process design concepts which rely mostly on empirical work, involving high experimental effort and cost. Additionally, the limited throughput potential, mostly caused by complex fluid dynamics and difficult phase separation, is problematic. In this work the current state and potential of micro technology for LLE is discussed based on literature data. Afterwards, process simulations with a distributed plug flow model are used to access the specific advantages of this technology and to identify critical process parameters.

The subject of previous work on liquid‐liquid extraction is complemented in this paper through the research activities in micro distillation. After a detailed literature study comparing the performance, strengths, and weaknesses of published micro distillation methods, critical process parameters based on model studies will be discussed. Apparative approaches to micro distillation are presented, where the capillary module used for distillation can provide a successful phase separation of gas‐liquid mixtures up to volume feeds of 10 mL min−1.

Design of microstructured process modules based on empirical approaches is time‐ and cost intensive. This becomes especially important for complex continuous operations, where several unit operations have to be efficiently combined for maximum process efficiency and economy. A concept for a model‐based design by an axial dispersion model is presented as a contribution to simplification and cost reduction. Simple microchannel structures with varying cross sections are evaluated with volume flows up to 20 mL min−1. The predictive accuracy of the model is demonstrated and assessed by selected examples.

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