Flow hydrogenation process development system:
This system is designed to allow the screening and development of hydrogenation reactions in the laboratory at a small scale. In addition to process research, this system is useful for client to operate continuously to deliver useful amounts of product, utilising flow rates of up to 10ml/minute. Normal development flow rates of around 1ml/min are usually used.
The system features the following:
- Flow rates of up to 10ml/minute
- Temperatures of up to 230°C as standard – much higher on request
- Simple and clean sampling system
- Automatic controlled nitrogen purging of product receiver
- Hydrogen leak alarm
- Thoughtful design taking into account experience working with hydrogen.
IntensiChem guarantees the scale-up of ANY process developed on its process development flow system to its pilot scale system – subject to reasonable conditions.
Contact IntensiChem for further information.
Flow hydrogenation pilot scale system:
This system is designed to operate at a 100x scale up, providing nominally 100ml/minute operation. This system, if operated continuously, is capable of producing tonnes of material per year if required. The pilot system acts as the bridge between the development laboratory and full commercial scale flow rates.
Again, IntensiChem guarantees the commercial scale up – to multiple tonnes per month of any process that has been successfully demonstrated in the pilot scale system.
Commercial flow systems:
After reviewing the information gained from the development and pilot scale systems, IntensiChem can prepare initial designs that will meet the needs of the customer. We can either work with the clients engineering team of choice, or we can provide a completed commercial scale flow hydrogenation skid. To achieve this, we would work closely with a team of UK based engineers to deliver commercial scale flow hydrogenation systems.
SERVICES – Process technology Development
IntensiChem can take your existing batch process and convert this to a continuous flow process. As with many conversions to flow, it is normal to see improvements in yield, reduction in impurities and a reduction in cost of installed infrastructure.
Some clients have expressed concerns about the materials used in the construction of their existing batch-based plant. Flow Chemistry systems, with inherently smaller reactor vessels, can be fabricated out of a range of materials that are completely fit for purpose. The usual is Hastelloy C276 but there are many options available.
Such design flexibility reduces the possibility of turning down incoming business due to incompatibility with plant materials. Customers can purchase an economical flow solution from IntensiChem specifying any material they require.
As with all new technology – there can be a barrier to entry that takes the form of an experience gap. Consider letting IntensiChem complement your development team accessing the experience gained for over a decade of flow hydrogenation development.
Elements of development can take the form of all or any of the following assessments:
- Proof of concept.
Can flow hydrogenation be carried out on the specific example of interest?
- Catalyst longevity studies.
How long does a charge of catalyst last?
- Regeneration studies.
Can the catalyst be re-generated after it has been deactivated through use? We can employ various strategies here to regenerate catalysts in situ, reducing the cost of the process.
- Design of experiments and consequential model generation.
Understanding the process and its edges of failure
- Predictive model testing.
Do the predicted optimal process parameters deliver the calculated yield and impurity?
- Alternative catalyst supplier assessments.
We understand that companies do not wish to be single sourced with regards to material supplies. Catalysts are no exception.
- Use testing of different suppliers or batches of input material.
It can be prudent to check whether different batches perform in the same way and do not unduly effect catalyst longevity.
- Pilot scale assessment of lab process.
Ensuring that the process is scalable and building the case for investment in the manufacturing plant.
- Design of commercial scale plant systems to support lab and pilot scale assessments.
The information gained during the development and scale up of the process needs to be translated into an industrial scale plant design.
The aim of the above development strategy is to deliver a world class, state of the art, commercial scale flow hydrogenation system for the client. This system will be cheaper to run, higher yielding, eliminate unwanted impurities and compliment customers’ existing flow processing efforts.