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Microchemical and Microphysical Systems. Prof. Attilio Citterio Dipartimento CMIC “Giulio Natta” https://iscamapweb.chem.polimi.it/citterio/it/education/course-topics/ School of Industrial and Information Engineering Course 096125 (095857) Introduction to Green and Sustainable Chemistry

Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

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Page 1: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Microchemical and Microphysical Systems.

Prof. Attilio Citterio

Dipartimento CMIC “Giulio Natta” https://iscamapweb.chem.polimi.it/citterio/it/education/course-topics/

School of Industrial and Information Engineering

Course 096125 (095857)

Introduction to Green and Sustainable Chemistry

Page 2: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Micro-chemical Systems and Processes:

Opportunity and Limits.

yield

energy efficiency

compact

Miniature reaction and other unit operations, show specific

advantages over conventional chemical systems.

Simplified Vision!

Page 3: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Modern Trends in Chemistry & Chemical

Engineering Crossing Discipline Boundaries.

Microfabrication

Microfluidics

Micro process

engineering

Catalyst &

materials science

ENABLING TECHNOLOGIES

FUNDAMENTAL SCIENCES

Mathematical

Modelling & simulation

Chemistry &

Chemical engineering

Green / sustainable

chemistry

Small-scale conti-

flow processing

Process

intensification

Novel means of chemical process engineering

Page 4: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Microchemical Systems –

Scale Down and Out.

MIT

~ 50 ml

~ 5 µliter

25°C

~ 5 liter flow?

temperature?

Pilot Production

~ 1 ml

Not to scale

SCALE

DOWN

UP UP

OUT

Page 5: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Fine-Chemical Microreactors

Production Plant.

Micromixer (1000 l/h)

Microtube reactor (100 l/h)

Micro heat exchanger (100 l/h)

Fine-chemical plant with 10 microstructured

production devices: launch at ACHEMA, May 15, 2006

IChemE Chemistry Innovation

KTN/Impact Awardaward (Whitehall, London)

IMM Plant in NATURE

Nature 442, 27 July 2006

Page 6: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Chemical Process Miniaturization.

“Miniature version of the regular thing.”

Same functionality per volume as macro

Miniature size is distinguishing factor

Portability often important

Often highly integrated

Microscale platforms for nanoscale

structures/materials.

New technologies and electronic controls.

Application of microfluids.

Page 7: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

What is Microfluidics?

Microfluidics enables precise control, manipulation and analysis of fluids in the microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry and are often referred to as microfluidic chips. Today the main application areas for microfluidics include:

Research and development chemistry DNA analysis and genomics

Microreactors

Cell based systems

The benefits of using microfluidic devices for laboratory applications include:

Reduction in sample volume and reagent usage

Improved resolution of separations

Ability to run reaction and analysis processes faster

Ability to run processes in parallel

Improved control of mixing and heating of fluids

Rapid mass transfer as a result of high surface area to volume ratios

Improved integration of process steps, for example reactions and separations

Development of new and improved detection methods

Simpler and cheaper disposable devices

Access to a wide range of fluidic geometries.

Microarrays

Clinical diagnostics

Liquid chromatography

Bio-defence sensors

Page 8: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Microfluidic Literature.

Nguyen, Wereley

Microfluidics

RC / 3.3 / 20

~110€; 500 pages

ISBN-1580533434. 2002

EH / 9.0 / 31

~80€; 260 pages

ISBN-3527307338, 2004

Henrik Bruus: "Theoretical

Microfluidics« (Oxford Master

Series in Physics)

~40€; 346 pages;

ISBN-10:0199235090. 2007

Microchemical Journal

Page 10: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Literature – Internet.

Fluids

Pressure

Kinetic

energy

Potential

energy

Bernoulli

Equation

Diffusion

Viscosity

Osmosis

Hydraulic Brakes

Blood flow Examples

Other Examples

Hydraulic Press

Static Fluid Pressure

Pascal’s Principle

Buoyancy

Archimedes

Principle

Poiseuille’s

Law

Turbulence Effects

non-Newtonian Fluids

Membrane Transport

Capillary Action

Surface Tension

Laplace’sLaw

Wall

Tension

Fluid

FrictionInternal

Energy

are

characterized

by

and

as well

as

summarized

in

leading

to

and

and

and

havehaveIn

motion

at rest

obey

leads

to leading

to

Page 11: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

About Microfluidics.

• „Micro“ means at least one of the

following features:

small volumes (μl; nl; pl; fl)

small size

low energy consumption

effects of the micro-domain

• Laminar flow

• 1 fl – 1 μl: 10 orders of magnitude

• still far away from molecular level.

1 m

m

1 μl

1 nl

1 nl

1 fl

Science Magazine 2 July 1999.

Page 12: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Chemical Reactor Scale.

Industry Laboratory Micro-system

Volume 30 m3 10-3 m3 3 10-11 m3

Scale-down 1 1:3 10-5 1: 10-12

Diameter 2 m 2 cm 20 mm

Surface

Volume

2

32

m

m

2

3200

m

m

2

3200 000

m

m

Page 13: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Key Benefit: Intensified Surface Phenomena

by Higher Surface Area-to-Volume Ratios.

constant

volume

Radii (mm)Su

rfa

ce

are

a / V

olu

me

(m

m-1

)

0 0.2 0.4 0.6 0.8 1

10

2030

4050

60708090

100

0

A B C

V constant

SA increasing

Ratio surface/volume

• intensified mass transport

toward the smaller dimensions

• Intensified heat transport

toward the smaller dimensions

• Intensified mixing

• Explosion-Safety improvement

Page 14: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Length & Time Scale of Chem. & Physical

Processes.

10-11 10-10 10-9 10-8 10-7 10-6 10-5 10-4 10-3 10-2 10-1 100 101 102

length scale [m]

105

104

103

102

101

100

10-1

10-2

10-3

10-4

10-5

10-6

tim

e s

cale

[s]

Micro structured

fluid dynamics

and transport

catalyst / reaction

chemistry

Page 15: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Temporal Scale and Typical Length of

Chemical Reactors.

10 m1 m100 mm10 mm1 mm100 mm10 mm1 mm

10-2

10-1

100

101

102

103

104

length

mean r

esid

ence t

ime [

s]

micro-structured

apparatus

milli-structured

apparatus

multi-tube

reactor

tube

reactor

Stirred tank

reactor

Page 16: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Micro-structured Components are Available.

Page 17: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

• Engineered structures with improved heat and

mass transport

• Self-assembling surfaces

• Nano-fabricated structures

• Biological enzymes as highly functional catalysts

MICRO CHEMICAL AND THERMAL SYSTEMS CONSIDERED AS A “PLATFORM” FOR NANOTECH.

Page 18: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Micro-structured Multichannel Reactor.

Flow conditions for typical fluids, Volume: VR = 5 cm3; L = 5 cm

gas (air)

liquid (water)

pressure drop, Dp=1 bar

turbulent

laminar

channel diameter, d [m]

Reyn

old

s n

um

ber,

Re [

-]

10-5 10-4 10-3

10-1

100

101

102

103

104

liquid (water)

gas (air)

pressure drop, Dp=1 bar

channel diameter, d [m]

10-5 10-4 10-3

10-5

10-4

10-3

10-2

10-1

100

101

channel diameter, d [m]

10-5 10-4 10-3

10-5

10-4

10-3

10-2

10-1

100

101

co

nta

ct

tim

e, t

[s]

Page 19: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Surface to Volume: Effective Transport.

Example: overall heat transfer coefficient.

Type Hx U (W·m-2·K-1)

Tubular 150-1200

Spiral 700-2500

Laminar 1000-4000

Micro-channel: 3800-6800 W·m-2·K-1

(500500 µm21.5 cm channels)

Page 20: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Properties of Micro Devices.

• Behavior of fluids at this scale

Wall effects dominate

• Surfaces and interfaces

Fouling

Multi-phase flow

Surface energy, tension, wettability

Dynamics -- start-up

• Equipment

Basic state measurements - P, T, phase, quality, composition

Density, thermal conductivity, electrical conductivity

Controls -- need to be integrated

Fluid flow and distribution

System homogeneity

Page 21: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

About Microfluidics (2).

• „Micro“ means at least one of the

following features

small volumes (μL; nL; pL; fL)

small size

low energy consumption

effects of the micro-domain

• Laminar flow

• Surface tensionCohesive forces bind molecules

each other.

Adhesive forces bind molecules

to surface.

Surface Tension g :

(work to be made to increase the surface of a unit quantity)

Compound : n-C6H14 H2O Hg

g (mN·m-1): 18.4 72.8 425.4 dw

dSg

Page 22: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

About Microfluidics (3).

• „Micro“ means at least one of the

following features

small volumes (μl; nl; pl; fl)

small size

low energy consumption

effects of the micro-domain

• Laminar flow

• Surface tension

• electrical surface charges

• diffusion

Electrosmotic Flow

EOF Laminar Flow

P

Pressure driven flow

u LRe

ReynoldsNumber < 2300

velocity u, density , traveled

length L, and viscosity of

the fluid

Page 23: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Market for Microfluidics.

Printing Industrial Automation

Flow sensors for

air conditioning

(HSG-IMIT)

50.000 units in 2005

Industrial dispenser Chem Process Engineering/ Power

systems

Page 24: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Market for Microfluidics (2).

Life Sciences!!!!

• Capillary Electrophoresis

• Lab on chip

• Drug delivery

• Clinical analysis

DNA

reaction fleece

start reservoirblood sample

transport zoneread-out windows plastic housing

separation fleece detection zone for

marker A, B & C

actuation fleece

Page 25: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Flow Sensors.

Working principle:

Thermal principles

Heaters & temperature sensors

• Anemometer

• Calorimeter

• Time of flight

Specifications:

Range: 15 μm/s – 1500 μm/s

Power: < 15 mW

Response time: < 1 ms

Application specific configuration

possible by adaption of flow

channels

Page 26: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Lab-on-a-Chip: Emulsion-Disk.

• Controlled droplet generation on

rotating disk

• Water-plug is focused by two oil

flows Φ0

• Production of water-droplets in oil

(W/O emulsion)

Volume: 5…22 nL

Rate: 0…300 drops / s

• High Reproducibility

Droplet diameter: CV < 2%

Page 27: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

DNA Microarray Printing.

Microarray

Spots, aligned in an arrayFluorescent signal

of one spot

Page 28: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

PipeJet Principle.

• Dispensing by direct volume

deflection

Polymer tube

Piezo-actuated piston

Fast displacement for jet

ejection

Short plateau

Slow release for capillary refill

• Unique strength of concept

Contact-free delivery of fluid

Simplest possible fluidic

geometry

Easiest packaging (mechanical

clamping).

Page 29: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

nL & pL Dosage: NanoJet.

• Dosage volume: 5 nL to 1.000 nL

• Dosage rate: 1.000 nL/s

• Viscosity range: 1 – 100 mPas

• Precision: better 5 %

Page 30: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

A New Class of Process Technology.

1 Å 1 nm 1 mm 1 mm 1 m 1 km

Smog

Gas Molecules

Viruses

Bacteria

Human HairRadius of Most Cells

Atmospheric dust

Tobacco smoke Beach Sand

Man

Single Transistor on IC IC Chip Personal Computer

Conventional Pumps and Valves

Conventional Reactors

and Heat Exchangers

Conventional Thermal and

Chemical Plant

Micromotor Rotors

Typical Microchannel widths

Micro Pumps and Valves

Microchannel Reactors

and heat exchangers

MicroThermal and

Chemical Systems

Page 31: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Features of a Continuous Microreactor System.

1. Precise control of temperature – easily set and changed - no temperature

gradients

2. Precise control of time - easily set and changed – quick hot reactions for

consistent particle size

3. Precise control of feeds/stoichiometry – rapidly investigate stoichiometry

by changing feed rates

4. Consistent and rapid mixing – ensures nucleation not precipitation

Tice, J.D. et al. Langmuir 2003 19, 9127-8133

5. No scale limitations – small scale for

optimisation; or “leave tap

running” to make kilograms per

day (100 g/h readily achievable)

6. Reproducible – same temperature,

same mixing, same reaction time,

every time

7. Immediate aqueous work up – simple

work up available if required

Page 32: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Micro Chemical Equipments and Systems.

• Microreactors

• Micro-channels

• Micro heat exchangers,

• Micromixers

• Separation Units and

• Micro analytical devices

Miniaturization:

High capacity

Light systems

Mass manufacture

Costly but versatile

MEMS, Mesoscopic Machine

Micro/Nano Systems

Microcats

Page 33: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Micro-Reactors.

• New reactor types which offer high capacity and high productivity.

• Microreactors are more versatile and less dependent on chemical-engineering operators

Provide useful amount of products

Are easy to use.

Page 34: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Micro-structured Multichannel Reactors.

Volume: VR = 5 cm3

Pressure drop: Δp = 1 bar

length: L= 5. cm

diameter: d= 100. μm

Number of channels: N= 12,740.

Specific surface: a= 40,000. m2/m3

Flow velocity: u= 0.63 m/s (water)

35. m/s (air)

Mass flow: Qm= 225. kg/h (water)

15. kg/h (air)

Page 35: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Micromixers.

Injection of Multiple Microjets

Schematic of a micromixer with injection of multiple microjets into a mixing chamber

1. The central element of the mixer

is a sievelike structure with a large

number of regular holes.

2. During operations, the mixing are

is filled with one liquid, and the

other liquid is injected into the

mixing volume through a multitude

of microholes.

3. Numerous microjets are generated

and increase the contact surface

between the two liquids.

4. The holes are positioned in rows

10-100 μm apart, which results

in short diffusional paths between

the jets.

5. Typical flowrates are in the μL/s,

the hole diameter is 10 μm, and the

height of the mixing chamber some

100 μm

Source: Quak Foo Lee

Page 36: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Micromixers.

1. Application: industrial chemical sensor

2. Flow range: 0.01 – 0.1 μL/s

3. Highly viscous flow with a Re < 1

4. The whole system consists of a

silicon/glass sandwich connected by

anodic bonding.

5. One channel structure is etched into

glass and the other into silicon.

6. In the region where the channels

overlap, they are separated by a

structured plate defined by an etchstop

layer.

7. Max. width = 300 μm

max. depth = 30 μm

8. The thickness of the structured

plate for separating the channels

in the glass and the silicon wafer

is 5 μm and the slit width 15 μm.

Multiple Flow Splitting and Recombination

Mixing units of a static micromixer with multiple slit-shaped injection openings

Source: Quak Foo Lee

Page 37: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Micromixers.

1. The fluid to be mixed are introduced

into the mixing elements in counter-flow

and stream into an interdigitated channels

with corrugated walls.

2. Typical channel widths = 25 or 40 μm

3. The channel configuration leads to a

periodical arrangement of flow lamellae

of the two fluids.

4. The lamellar flow leaves the device

perpendicular to the direction of the feed

flows and, because of the thinness of the

lamellae, fast mixing takes place by

diffusion.

5. The corrugated channel walls increase the

contact surface of the lamellar streams and

improve the mechanical stability of the

separating walls.

Multilamination of Fluid Layers

Multilamination of streams in channels with corrugated walls, leading to fast mixing by diffusion.

Scanning electron micrographs of a mixing element based on multilamination of thin fluid layers. The device consists of 2 × 15 interdigitated microchannels with corrugated walls, fabricated by LIGA technology.

Source: Quak Foo Lee

Page 38: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Gasoline Vaporizer.

• 50 kWe capacity: Four

cells each of microchannel

reactors and heat

exchangers

• Volume: 0.3 L

• Processes/combusts 1400

SLPM

1999 - R&D Award Winner

Page 39: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Micro Heat Exchangers.

Channel diameter: ~50 – 500 μm

Channel length: 20 – 100 mm

No of channel: 200 – 1000

Specific surface: 104–105 m2/m3

Micro heat exchanger with connections for fluid supply

(source: Forschungszentrum Karlsruhe)

Cross-Flow Heat Exchange in Stacked Plate Devices

Counterflow Heat Exchange in Stacked Plate Devices

Page 40: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

• Heat fluxes: 100+ watts/cm2

• Low pressure drops: 1-2 psia

• High convective heat transfer

coefficients

Liquid phase: 10,000 - 15,000

W·m-2·K-1

Evaporating phase: 30,000 -

35,000 W·m-2·K-1

Advantage: Rapid Heat and Mass Transport

Microchannel Heat Exchangers.

Page 41: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Microseparators.

Schematic of solute exchange between immiscible fluids in partially overlapping microchannels (left) and scanning electron micrograph of the cross section of the partially overlapping microchannels (right),

Exchange between Immiscible Fluids

Exchange between Immiscible Fluids

Scanning electron micrograph (left) and schematic (right) of an extraction unit with adjacent channels for two fluids with slits, oblique to the flow direction, for exchange between the two phases.

Aqueous

Aqueous

Organic

Organic

Page 42: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Microseparators.

Filtration, Diffusion, and Aerodynamic Separation

Scanning electron micrograph of a cross-flow filter consisting of lamellae arranged at an angle of attack to the flow direction

• In the macroscopic range, filtration and sieve structures are often carefully designed

with regard to the shape and position of the openings.

• In the microscopic range usually porous materials with irregular pattern are applied.

• Microfabrication methods allow the production of completely isoporous microfilters

(pore dimensions in the micrometer range) from a wide variety of materials, whereby

the size, shape, and position of each pore can be designed.

• Special configurations for cross-flow filters for concentrating suspended particles/cells.

• In the case of membrane units, microfabricated devices are useful as carrier structures

with integrated inlets and outlets for fluids.

Page 43: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

UOP LLC

Miniaturization of Analytical Systems.

Page 44: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Mechanism Tools.

LAMIMS MRX Atm. TSR TEOM

TAPPulsedMRX

Reactivity Testing

ZLC

Calorimetry Isotopic Labeling

SSITKA

Process Model

ReactionMechanism

Heat of Ads. Capacity

Number of Intermediates

lifetimeDiffusion

Characterization UOP LLC

Page 45: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

CPM – H2 Production.

Page 46: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Paal-Knorr Synthesis via Microreactors.

FutureChemistry’s FlowSyn on

Micronit Microfluidics microreactors

Diketone

Amine

Quenching

agent

Microreactor

ProductTemperature control

Collection and

off-line analysis

P2

P3

P1

M

M

RI

Page 47: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Miniaturization of Chemical Reaction:

Synthesis of Carbamates.

Hemantkumar R. Sahoo, Jason G. Kralj, and Klavs F. Jensen, Angew. Chem., 2007, 46, 5704-5708.

microreactor

single phase mR3

mS2

mR2

mS1

microsepaator

Aq waste

Alcohol

Carbamate

N2

isocyanate

Sodium

azide (aq)

gas-liquid-solid

gas-liquid

separation

liquid-liquid

separation

Acyl

chloride

Sintesi di carbammati via azidi

Experimental setup for carbamate synthesis.

mR1, micro-reactor for conversion of acyl chloride to organic

azide;

mS1, quantitative separation of organic and aqueous streams;

mR2, microreactor loaded with solid acid catalyst for

conversion of organic azide to isocyanate;

mS2, quantitative separation of gaseos N2 from the liquid;

mR3, microreactor for reaction of isocianate and alcohol to

carbamate.

Page 48: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Corning Glass Microreactors.

Pressure drop

1 millimeter

Mixing

300 micron

Heat exchange layer

Heat exchange layer

Reactants

Page 49: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Fluidic Modules: Concept and Library.

Page 50: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Engineered Reactor Components.

O-ring seals

Connectors

Interfaces

Frames

Fluidic Modules

Standard

Fittings

Tubing

Sensors

Instrumentation

(Pressure relief

valve…)Add-on

Labelling (insulation…)

Page 51: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Phloroglucinol-Type Kolbe Schmitt -

Synthesis in Microreactors.

0

10

20

30

40

50

60

0 50 100 150 200 250 300

Yie

ld (

%)

Temperature (°C)

Page 52: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Kolbe Schmitt-Synthesis: High P,T-Processing.

V. Hessel, C. Hofmann, P. Löb, J. Löhndorf,

H. Löwe, A. Ziogas

Org.Proc. Res. Dev. 9, 4(2005) 479-489

• Pressure: 40-70 bar

• Temperature: 100-220°C

• Reaction time: 4 –390 s

Reduction of reaction time

by ~2000

Increase in space-time

yield by factor 440

Increase in productivity by

factor 4

High p,T

Page 53: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Modelling Study on Styrene Solution

Polymerization.

Thermal phenomenon

convection/conduction

Hydrodynamics

Navier-Stokes equations

Reaction, convection

and diffusion of chemicals

Kinetics constant

depend on temperature

Heat released by

polymerization

Convection

Viscosity affected by

Reaction yield

ConvectionViscosity affected by

Reaction temperature

V. Hessel, C. Serra, H. Löwe,

G.Hadziioannou, Chem. Ing.

Techn.77, 11 (2005) 39-59, (Polymerization rate)

Page 54: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Microstructured Epoxidation Reactor.

Reaction

(microstructured)

Mixing

(microstructured)

H2O2 evaporation

(microstructured)

Model Synthesis:

Features:

• Modular (unit operations,

capacity)

• Multi-purpose (catalyst

and reaction)

• Reaction under pressure

• Reactions in the explosive

regime Degussa

Page 55: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Radical Polymerization Reactor.

Page 56: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Where to Apply Microchemical Technology?

Direct routes from hazardous systems

Routes at increased concentration or even solvent-free

Routes at elevated temperature and/or pressure

Routes mixing the reactants ‘all at once’

Routes using unstable intermediates

Routes in the explosive or thermal runaway regime

Routes omitting the need of catalysts and auxiliary agents

DEVELOPMENT OF REACTORS TO ENABLE CHEMISTRY RATHER

THAN SUBDUING CHEMISTRY AROUND THE REACTOR

V. Hessel, P. Löb, H. Löwe, Curr. Org. Chem. 9, 8 (2005) 765-787Jähnisch, K.; Hessel, V. et al.; Angew. Chem. Intern. Ed. 43, 4 (2004) 406-446

Page 57: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Scientific and Technological Drivers in

Surface-Nano Applications.

SCIENTIFIC DISCIPLINES

TECHNOLOGICAL DRIVERS

FROM SURFACE TO NANOc

om

ple

xit

y

timephysics

chemistry

material science

applied physics

mechanical engineering

chemical engineering

electrical engineering

environmental sciences

biochemistry

biology

medicine

informatics

surfaces

interfaces

clusters

thin films

coatings

superlattices

nanostructures

bionano

transistors/electronics

aerospace

catalysis

interconnects

magnetism

electrochemistry/corrosion

tribology (friction/adhesion)

surfactants

optoelectronics

photochemistry

environment

polymers

embrittlement

sencors/actuators

molecular electronics

spintronics

biocompatibility

membranes

quantum dots/nanowires

nanomechanics

biosensors/bioelectronics/…

Page 58: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

Phenomena and Techniques in Surface-

Nano Applications.

TECHNIQUES

PHENOMENA

FROM SURFACE TO NANOc

om

ple

xit

y

time

ultra-high vacuum

instrumentation

characterization

predictive theory

analytic theory

synthesis: MBE, …

synchroton radiation

Imaging: STM, HREM, …

atomic manipulation

non-UHV

tomography

surfaces

interfaces

clusters

thin films

coatings

superlattices

nanostructures

bionano

thermodynamics

geometric structure

electronic structure

magnetic structure

adsorption

chemical reactions

mechanics

optical properties

vibrations

dynamics

growth

optomagnetism

soft matter

self-assembly

multifunctionality

Page 59: Microchemical and Microphysical Systems. · 2019-10-20 · microliter to picoliter range. Microfluidic devices are fabricated using techniques developed in the semiconductor industry

Attilio Citterio

References on Microreactors and

Microchemical Systems.

1. S. Born, E. O'Neal, K.F. Jensen "Organic Synthesis in Small Scale Continuous Flow: Flow Chemistry" Organic

Synthesis in Small Scale Continuous Flow: Flow Chemistry, In Comprehensive Organic Synthesis II (Second

Edition), edited by Paul Knochel, Elsevier, Amsterdam, 2014, Pages 54-93,

2. Patrick L. Mills, David J. Quiram, James F. Ryley, Microreactor technology and process miniaturization for catalytic

reactions—A perspective on recent developments and emerging technologies, Chemical Engineering Science, 2007,

62, 24, 6992

3. Paul Watts, Charlotte Wiles, Recent advances in synthetic micro reaction technology, Chem. Commun., 2007, 5, 443

4. Nam-Trung Nguyen, Micromixers, 2008, 293

5. D. Ghislieri, K. Gilmore, P. H. Seeberger Control for divergent, continuous, multistep syntheses of active

pharmaceutical ingredients” Angew. Chem., I.E. 2015, 54, 678–682

6. C. Y. Park, Y. J. Kim, H. J. Lim, J. H. Park, M. J. Kim, S. W. Seo, C. P. Park “Continuous flow photooxygenation of

monoterpenes” RSC Advances 2015, 5, 4233–4237

7. Christoph Tonhauser, Adrian Natalello, Holger Löwe, Holger Frey, Microflow Technology in Polymer Synthesis,

Macromolecules, 2012, 45, 24, 9551.

8. P. Wiktor, A. Brunner, P. Kahn, J. Qiu, M. Magee, X. F. Bian, K. Karthikeyan, J. LaBaer “Microreactor array device”

Scientific Reports 2015, 5, Article number: 8736, doi: 10.1038/srep08736

9. Jun-ichi Yoshida, Heejin Kim, Aiichiro Nagaki, Green and Sustainable Chemical Synthesis Using Flow Microreactors,

ChemSusChem, 2011, 4, 3, 331

10. Florence Bally, Christophe A. Serra, Volker Hessel, Georges Hadziioannou, Homogeneous Polymerization: Benefits

Brought by Microprocess Technologies to the Synthesis and Production of Polymers, Macromolecular Reaction

Engineering, 2010, 4, 9-10, 543

11. Jun Yue, Jaap C. Schouten, T. Alexander Nijhuis, Integration of Microreactors with Spectroscopic Detection for

Online Reaction Monitoring and Catalyst Characterization, Industrial & Engineering Chemistry Research, 2012, 51,

45, 14583

12. Li-Hua Du, Xi-Ping Luo, Lipase-catalyzed regioselective acylation of sugar in microreactors, RSC Advances, 2012, 2,

7, 2663