Batch to flow conversion, our service
What is the worst could happen when developing a flow processes? Leaks, pump fails, blockages – we had them all.
Yet, it is worth it. Over the last 4 years doing feasibility studies of flow chemical production, we doubled the yield in a Friedel-Crafts process, halved the energy use in a large-scale exothermic chemistry, succeeded in controlled precipitation, and intensified a profusion of liquid-liquid processes from hours to minutes with rapid mixing in our SABRe systems.
Let’s talk if you have a process in mind!
We not only provide flow reactors, we also help using them. We provide services and help to
– study feasibility of a batch to flow conversion for the particular process,
– estimate the benefits of the flow operation,
– optimise the flow process to maximise the benefits of flow,
– deliver the reactors or the complete flow system.
The first step is always a quick literature review. Not all the processes would benefit from flow and – we start with a quick process assessment and this assessment is free.
After all, our interest is in the large-scale flow reactors. We do not want to do projects for project’s sake. We want your process to succeed and to bring the benefits of flow chemistry.
Read more on advantages of flow chemistry
What is flow chemistry and what it means for a real-life chemist – that is what we discuss in a separate page.
The first step – experimental feasibility study
We do rapid process assessment – we study several experimental conditions to understand if the process could be performed in flow, and to estimate process conditions and throughput.
The feasibility study provides initial indications on the batch-to-flow conversion and an outline of the flow benefits such as
– increased yield
– decreased impurity
– higher product quality
– reduction in reactant excess or solvents
– dramatically faster reaction rate
Our multi-CSTR SABRe system allows a unique set of flow chemistries to be undertaken, minimising mass transport issues in a range of reactions.
– reactor volume of 30 mL to 120 mL; allowing for intensification screening of facile reaction conditions: Residence time/flow rates, temperature, concentration of reagents.
– temperature range of cryogenic to 200°C, 100 bar maximum pressure.
– ability to customize unit for specific demands of the chemistry by adding reagents into different CSTRs within the flow reactor.
– capable of supporting gram to kilo, to multi-ton scale production.
– we can produce 100s of gram samples where there is adequate supply of starting material.
Our multi-CSTR SABRe system allows a unique set of flow chemistries to be undertaken, minimising mass transport issues in a range of reactions.
– reactor volume of 30 mL to 120 mL; allowing for intensification screening of facile reaction conditions: Residence time/flow rates, temperature, concentration of reagents.
– temperature range of cryogenic to 200°C, 100 bar maximum pressure.
– ability to customize unit for specific demands of the chemistry by adding reagents into different CSTRs within the flow reactor.
– capable of supporting gram to kilo, to multi-ton scale production.
– we can produce 100s of gram samples where there is adequate supply of starting material.
Benefit from SABRe technology at scale, namely:
– best in class mixing performance for multiphase processes
– rapid heat transfer rates for temperature control
– mixing performance that remains stable on scale-up
– heat transfer performance that remains stable on scale-up