Countercurrently Operated Reactive Extractor with an Additively Manufactured Enzyme Carrier Structure

Abstract

Precisely designed structures inserted in hybrid reactors can be used to control multiphase hydrodynamics and to act as a catalyst carrier simultaneously. While numerical simulations with computational fluid dynamics have limitations regarding the complex interactions in multiphase flows, performing experiments using rapid prototyping (RP) offers the possibility of a fast fabrication and verification of tailor-made structures for specific flow characteristics, efficient mass transport, and high conversion rates. In the presented work, the development of a countercurrently operated additively manufactured reactor for the decarboxylation of ferulic acid to 2-methoxy-4-vinylphenol (MVP) along in situ extraction with n-heptane is shown. Here, the use and optimization of periodic open-cell structures (POCSs) as a carrier for the enzyme phenolic acid decarboxylase and a distributor for the extraction phase are targeted. By RP of transparent structures and their examination concerning the induced flow characteristics of colored heptane, a structure could be optimized for the specific reaction system. The additive manufacturing of POCSs and their application in a hybrid countercurrently operated reactor enabled the conversion of FA and a low concentration of the competitively inhibiting product MVP in the reaction phase via efficient in situ extraction via the dispersed heptane phase.

Characterization of Liquid-Phase Distribution in 3D Printed Structured Packings with an Enclosed Column Wall

“…In chemical engineering, additive manufacturing (AM), also known as three-dimensional (3D) printing, offers various advantages for the design of tailored and optimized structures, improving heat and mass transfer efficiencies. Thus, applications range from the design of complete heat exchangers − or microengineering devices − to the design of catalyst − or enzyme , support structures for chemical reactors.…”

Electrical Capacitance Volume Tomography (ECVT) for Characterization of Additively Manufactured Lattice Structures (AMLS) in Gas-Liquid Systems

“…Since the rapid rise of additive manufacturing in the last decade and the steady influx of new technical manufacturing possibilities of this innovative technology, it is also gaining increasing acceptance in chemical process engineering [14][15][16][17][18][19][20][21][22]. As a result of the newly gained degrees of freedom in the design and layout of reactors, new concepts for the development of customized reactor solutions are on the way [23][24][25][26][27]. One current research area is the development of Additively Manufactured Lattice Structures (AMLS) for tailor-made adjustment of fluid properties for gas-liquid contact apparatuses.…”

“…AMLS and, in particular, POCS are characterized by several advantages: Their use increases mass transfer while maintaining a comparatively small pressure drop (high energy efficiency) [28][29][30] and they also act as a static mixer [31]. Furthermore, POCS have a high surface-to-volume ratio and thus additionally enable a targeted use of heterogeneous catalysts or, in the case of a biochemical reaction, act as a carrier for immobilized enzymes [25]. Additional degrees of freedom in operation can be achieved by the use of interwoven structures, so-called "interPOCS" [18], or by the choice of advanced structural materials (smart materials), e.g., autonomous modes of operation can be achieved using special hydrogels [24].…”

Smart Structures—Additive Manufacturing of Stimuli-Responsive Hydrogels for Adaptive Packings

“…The groups led by Schwieger and Freund applied periodic open-cell structures in a trickle bed reactor and investigated their influence on the gas–liquid distribution as well as the liquid hold-up behavior and pressure drop in two-phase flows . Other groups have demonstrated intensified heat, , and mass transfer performances through the utilization of POCS in multiphase flows or adapted POCS as enzyme carrier for enzymatic biochemical processes with extractive product separation . Spille et al have recently shown the potential of POCS to homogenize and tailor the gas–liquid properties due to this kind of structured packing …”

“…28 Other groups have demonstrated intensified heat, 25,30 and mass transfer 31 performances through the utilization of POCS in multiphase flows or adapted POCS as enzyme carrier for enzymatic biochemical processes with extractive product separation. 34 Spille et al have recently shown the potential of POCS to homogenize and tailor the gas−liquid properties due to this kind of structured packing. 35 A major advantage of POCS is the flexibility of design of these structures, as the choice of cell shape and cell unit size can be adjusted to fit the requirements of the process.…”