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Micro processing techniques save material and energy in the chemical industry
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00:00:00.180 [Music] 00:00:04.32900:00:04.339 whether it's pharmaceuticals or 00:00:07.09900:00:07.109 cosmetics production methods are similar 00:00:10.61000:00:10.620 across the chemicals industry despite 00:00:17.38000:00:17.390 complicated technology the actual 00:00:20.09000:00:20.100 chemical reaction commonly takes place 00:00:22.37000:00:22.380 in a so called batch reactor or boiler 00:00:28.35900:00:28.369 that means even in large-scale 00:00:30.76900:00:30.779 facilities chemistry works basically 00:00:33.41000:00:33.420 like it does in the lab the reagents 00:00:39.88900:00:39.899 flow together in a vessel but that 00:00:43.01000:00:43.020 doesn't provide optimal mixing the 00:00:45.59000:00:45.600 vessel contains a variety of substances 00:00:47.54000:00:47.550 in different concentrations called 00:00:50.00000:00:50.010 concentration hotspots as well as a 00:00:54.77000:00:54.780 range of temperatures called 00:00:56.75000:00:56.760 thermal hotspots 00:00:58.93000:00:58.94000:01:03.64000:01:03.650 experts describe this situation as 00:01:06.55000:01:06.560 reduced process control in order to 00:01:13.64000:01:13.650 ensure the most efficient use of raw 00:01:15.74000:01:15.750 materials and energy as possible in the 00:01:18.17000:01:18.180 chemicals industry process control must 00:01:21.32000:01:21.330 be continuously optimized chemists at 00:01:34.63900:01:34.649 the company air Feld micro technique in 00:01:37.34000:01:37.350 Vendela time germany have developed 00:01:39.95000:01:39.960 their own system of carefully 00:01:41.60000:01:41.610 controlling the reaction of combined 00:01:43.60900:01:43.619 chemicals the modular micro reaction 00:01:48.91900:01:48.929 system or mm RS consists of several 00:01:52.34000:01:52.350 components through which reagents flow 00:01:54.85900:01:54.869 inside tiny channels the small stainless 00:02:00.74000:02:00.750 steel parts carry out a variety of 00:02:02.99000:02:03.000 functions like that of a mixer heat 00:02:05.48000:02:05.490 exchanger and sensor the chemists place 00:02:09.94900:02:09.959 a special reactor in the middle of this 00:02:11.90000:02:11.910 unit the channels are only a few 00:02:16.25000:02:16.260 millimeters wide in all of the 00:02:18.47000:02:18.480 components that allows for a very rapid 00:02:21.44000:02:21.450 exchange of substances and because of 00:02:24.25900:02:24.269 the large surface to volume ratio the 00:02:27.25900:02:27.269 chemicals are quickly able to absorb and 00:02:29.63000:02:29.640 give off heat 00:02:34.49000:02:34.500 the chemists place the entire unit under 00:02:37.64000:02:37.650 an exhaust hood chemicals flow through 00:02:40.40000:02:40.410 hoses into the tiny channels the flow 00:02:45.35000:02:45.360 plate micro reactor used in the unit is 00:02:48.08000:02:48.090 also equipped for what's known as 00:02:50.48000:02:50.490 lithium this reaction is often used for 00:02:55.61000:02:55.620 the production of active ingredients and 00:02:57.74000:02:57.750 pharmaceuticals the substrate bromo 00:03:05.27000:03:05.280 anisole flows through the reactor in 00:03:07.69900:03:07.709 channels that are only a few millimeters 00:03:09.94900:03:09.959 wide at the same time the reagent 00:03:14.30000:03:14.310 butyllithium flows into the reactor 00:03:19.78000:03:19.790 right after the two chemicals are 00:03:22.28000:03:22.290 combined they flow through a meandering 00:03:24.56000:03:24.570 structure just a few tenths of a 00:03:26.90000:03:26.910 millimeter wide that leads to a rapid 00:03:29.90000:03:29.910 mixing of the two reagents 00:03:36.64900:03:36.659 during the reaction 00:03:38.61000:03:38.620 lithium replaces bromine that creates an 00:03:43.05000:03:43.060 intermediate product the reaction also 00:03:51.63000:03:51.640 releases great amounts of heat 00:03:55.95000:03:55.960 and that leads to the destruction of 00:03:59.77000:03:59.780 some emerging molecules 00:04:07.52000:04:07.530 if the process is not cooled more raw 00:04:10.52000:04:10.530 materials are needed to retain desired 00:04:12.65000:04:12.660 amounts of the product and that makes 00:04:15.38000:04:15.390 efficient cooling vital for the 00:04:17.47900:04:17.489 reactions success in the flow plate 00:04:26.66000:04:26.670 reactor the chemical reaction takes 00:04:29.33000:04:29.340 place in a small channel on a large flow 00:04:32.48000:04:32.490 plate that is cooled from below by a 00:04:34.79000:04:34.800 cooling agent the large surface area 00:04:38.45000:04:38.460 ensures an optimal heat exchange and the 00:04:41.72000:04:41.730 chemicals can be cooled with less energy 00:04:44.00000:04:44.010 than needed in a large vessel that not 00:04:49.43000:04:49.440 only saves energy fewer raw materials 00:04:52.52000:04:52.530 are also needed since the process 00:04:54.56000:04:54.570 creates fewer unwanted byproducts 00:04:59.92000:04:59.930 shortly afterwards 00:05:01.61000:05:01.620 acetone flows into the channel it also 00:05:04.88000:05:04.890 mixes with the intermediate product in a 00:05:07.34000:05:07.350 meandering structure the acetone is 00:05:11.45000:05:11.460 taken up by the intermediate product the 00:05:14.84000:05:14.850 desired carbon compound is created and 00:05:17.54000:05:17.550 that results in the end product 00:05:20.20000:05:20.210 inorganic compound with very specific 00:05:23.40900:05:23.419 characteristics if this experiment had 00:05:28.64000:05:28.650 taken place as usual in a batch reactor 00:05:31.28000:05:31.290 a conventional vessel a low temperature 00:05:34.76000:05:34.770 of minus 80 degrees Celsius would have 00:05:37.64000:05:37.650 been necessary to adequately cool down 00:05:39.77000:05:39.780 the reagents because of the lawns of 00:05:43.25000:05:43.260 reactors efficient cooling a low 00:05:45.80000:05:45.810 temperature of only about minus 20 00:05:48.32000:05:48.330 degrees Celsius is enough to stabilize 00:05:50.24000:05:50.250 the lithium process at eto affiliation 00:05:56.06000:05:56.070 is a good example of very fast 00:05:57.88000:05:57.890 organometallic reactions where a large 00:06:00.46900:06:00.479 amount of dislocation is necessary to 00:06:02.60000:06:02.610 extract energy from the bench I think 00:06:05.03000:06:05.040 that's not energy efficient the micro 00:06:07.21900:06:07.229 reactor allows you to release heat very 00:06:09.08000:06:09.090 quickly and work under strictly defined 00:06:11.54000:06:11.550 conditions and that lets you manufacture 00:06:13.90900:06:13.919 products with greater energy efficiency 00:06:15.44000:06:15.450 and fewer byproducts 00:06:20.27000:06:20.280 the chemists use other reactors too for 00:06:23.91000:06:23.920 their experiments 00:06:26.03000:06:26.040 this new provo reactor contains eight 00:06:29.25000:06:29.260 long channels one and a half millimeters 00:06:31.65000:06:31.660 high and 12 millimeters wide the 00:06:35.40000:06:35.410 engineers insert three rubber-like grids 00:06:37.73000:06:37.740 that creates a highly complex structure 00:06:40.65000:06:40.660 in the channels interiors the reactor is 00:06:45.51000:06:45.520 again mounted inside the modular micro 00:06:47.97000:06:47.980 reaction system and placed under the 00:06:50.25000:06:50.260 hood 00:06:53.22000:06:53.23000:06:55.77900:06:55.789 this experiment is focused on ethics 00:06:58.70000:06:58.710 elysion a reaction that is commonly used 00:07:01.99900:07:02.009 in the production of materials for the 00:07:03.92000:07:03.930 cosmetics and paint industries 00:07:06.61000:07:06.620 manufacturers use toxic and highly 00:07:09.05000:07:09.060 flammable ethylene oxide for this 00:07:11.36000:07:11.370 purpose the ethylene oxide flows through 00:07:20.93000:07:20.940 the channels together with another 00:07:22.37000:07:22.380 reagent a type of alcohol the complex 00:07:26.81000:07:26.820 grid structure ensures a thorough cross 00:07:29.45000:07:29.460 mixing of the reagents and that leads to 00:07:37.87900:07:37.889 an even distribution of reagents in the 00:07:40.40000:07:40.410 channel system as a result there's no 00:07:44.39000:07:44.400 formation of concentration hotspots and 00:07:46.79000:07:46.800 the reaction is controlled the ethylene 00:07:51.11000:07:51.120 oxide is taken up by the oxygen atom of 00:07:54.37900:07:54.389 the alcohol group this procedure repeats 00:07:57.62000:07:57.630 itself several times a polymer is formed 00:08:01.62900:08:01.639 since the reagents are homogeneous ly 00:08:04.67000:08:04.680 distributed in the reactor the same 00:08:07.46000:08:07.470 amount of molecules always accumulate on 00:08:10.31000:08:10.320 an alcohol group identical polymers are 00:08:13.25000:08:13.260 formed with the desired length and with 00:08:16.46000:08:16.470 few byproducts 00:08:18.80000:08:18.81000:08:21.52000:08:21.530 because of its structure the MIT prova 00:08:24.58900:08:24.599 offers a very large surface-to-volume 00:08:26.71900:08:26.729 ratio of 2,000 square meters of reactor 00:08:30.49900:08:30.509 wall surface per cubic meter of fluid 00:08:33.29000:08:33.300 volume that means the extreme exothermic 00:08:37.61000:08:37.620 reaction can be adequately cooled that's 00:08:41.38900:08:41.399 vital since the starting product is 00:08:43.63900:08:43.649 highly explosive the reactor enables an 00:08:47.99000:08:48.000 easily controllable and safe process 00:08:51.13900:08:51.149 flow with few by products since 00:08:56.81000:08:56.820 reactions in the flow plate and me probe 00:08:59.09000:08:59.100 of reactors take place in small channels 00:09:01.67000:09:01.680 with a diameter of just a few 00:09:03.86000:09:03.870 millimeters or micro millimeters the 00:09:06.62000:09:06.630 process is highly defined and that makes 00:09:09.80000:09:09.810 upscaling relatively simple the channel 00:09:13.49000:09:13.500 cross sections and the reactors are 00:09:15.35000:09:15.360 simply enlarged or several channels are 00:09:18.25900:09:18.269 arranged parallel to each other these 00:09:21.50000:09:21.510 so-called micro and milli reaction 00:09:23.90000:09:23.910 technologies make possible to production 00:09:26.32900:09:26.339 of several thousand tons of a given end 00:09:28.73000:09:28.740 product each year from pharmaceuticals 00:09:32.09000:09:32.100 and fine chemicals to petrochemicals and 00:09:35.18000:09:35.190 food chemistry 00:09:42.75000:09:42.760 Himiko or micro and milli reactors have 00:09:45.69000:09:45.700 great potential as process intensifying 00:09:48.06000:09:48.070 instruments in the chemicals industry 00:09:51.50000:09:51.510 estimates claimed that about fifty 00:09:53.58000:09:53.590 percent to find chemicals and 00:09:55.08000:09:55.090 pharmaceuticals 00:09:55.89000:09:55.900 could be produced faster cheaper and 00:09:58.11000:09:58.120 more effectively through a continuous 00:10:00.09000:10:00.100 process in micro and milli reactors 00:10:01.98000:10:01.990 instigated co2 income each year the 00:10:07.71000:10:07.720 German chemicals industry generates 00:10:09.60000:10:09.610 revenues of some 190 billion euros 00:10:13.76000:10:13.770 there are several providers of micro and 00:10:16.71000:10:16.720 milli process technology in Germany 00:10:18.86000:10:18.870 their technology can contribute to 00:10:21.63000:10:21.640 substantial savings of energy and raw 00:10:23.76000:10:23.770 materials in the chemicals industry and 00:10:27.65000:10:27.660 help secure Germany's position as the 00:10:30.81000:10:30.820 world's third largest chemical supplier 00:10:34.61000:10:34.62000:11:01.44000:11:01.450 you
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