continuous flow reactor, batch reactor, green chemistry, application , flow reactor, type of flow reactor , synthetic applications

1. FLOW CHEMISTRY
CONTINUOUS FLOW REACTORS
SUBMITTED BY:
UPASANA SHARMA
M.PHARMA
(PHARMACEUTICAL
CHEMISTRY)
SUBMITTED TO:
Dr. RAJNISH KUMAR
(PROFESSOR)
NOIDA INSTITUTE OF ENGINEERING AND TECHNOLOGY (PHARMACY INSTITUTE)
GREATER NOIDA

2. CONTENT:
REACTORS
FLOW CHEMISTRY
PRINCIPLE
WORKING PRINCIPLE
BATCH AND FLOW REACTORS
 TYPES OF FLOW REACTON
ADVANTAGES
SYNTHETIC APPLICATION
CONCLUSON
REFRENCES

3. REACTORS :
REACTORS :
RREACTORS :
• A reactor is a vessel or system in which a chemical reaction takes
place. Example:
• Batch reactors
• Continuous flow reactors
• Continuous stirred tank reactor
• Plug flow reactors
• Fixed bed reactors
• Fluidized bed reactors
• The choice of reactor type depends on various factors, including the
type of reaction, the reaction rate, the required product yield, and the
required reaction conditions.

4. FLOW CHEMISTRY :
• It discover the early 20th century, with the development of continuous-flow processes in
the chemical industry.
• Professor Steven Ley, with his research group at the University of Cambridge, began
exploring the use of microreactors and other flow technologies in the late 1990s
• .Another one The Professor Klavs Jensen, with his research group at the Massachusetts
Institute of Technology (MIT), developed a range of microreactors and flow
technologies for chemical synthesis.
• Jensen's work paved the way for the commercialization of flow chemistry systems and led
to the establishment of several companies, including Syrris Ltd. and Vapourtec Ltd
• .Flow chemistry, also known as continuous-flow chemistry or microreactor technology, is
a type of chemical synthesis that involves the use of continuous-flow reactors instead
of traditional batch reactors.

5. PRINCIPLE:
REACTANT MIXTURE AT
CONSTANT RATE ,AID OF
PUMPAND OTHER MEANS
OF FLOW CONTROL
(PISTON PUMP, SYRINGE
PUMP)
TUBES AND SERIES OF
TUBES (TUBULAR
REACTOR,PLUG FLOW
REACTOR)
REACTOR (ALLOW TO
REACT)
PRODUCT MIXTURE
COLLECTED AT OUTLET

6. WORKING PRINCIPLE:
1.Feeding of reactant:
Constant flow rate maintain constant concentration of reactant with the reactor
2.Mixing of reactant:
to get homogeneous mixture degree of mixing is controlled
3.Reaction:
reactant mixed. reaction occur ,rate reaction controlled by factor- catalyst, temperature,
pressure, concentration of reactant
4.Collection of product:
flow rate maintain, constant concentration of product
5.Monitoring and control:
optimal condition, temperature sensor, flow meter, pressure sensor , computer controlled feedback system

7. a) Pumps: used to deliver reproducible quantities of solvents and reagents; the usual types are piston,
peristaltic, syringe or gear centrifugal pumps
b) Reaction loops: used to introduce small volumes of reagents
c) T-piece: primary mixing point, where reagents streams are combined
d) Coil reactor: provides residence time for the reaction
e) Column reactor: packed with solid reagents, catalysts or scavengers
f) Back pressure regulator: controls the pressure of the system
g) Downstream unit: in-line analytics, work-up operations, etc

8. • Scaling out-Run process longer, easiest
method
• Numbering –up- multi reactors in parallel
used
• Scaling-up: use of larger continuous reactor
BATCH REACTOR
1) Stoichiometry-molar ratio of reagent
2) Reaction time determined by vessels is
stirred under fixed condition
3) Reaction kinetics controlled by reagent
exposure time under specified condition
4) Flexibility more and initial product of new
compound possible
5) Small quantity production
6) Reagent and concentration vary over product
7) Time and mixing is important that affect
kinetics of reaction
8) Mixing and mass transfer less and efficient
FLOW REACTOR
1) Stoichiometry- ratio of flow rate and molarity
2) Reaction time and residence time (reactant
in reactor zone)- τ = V/q (V: volume of system
and q: flow rate of system)
3) Reaction kinetics controlled by flow rate of
reagent streams
4) Flexibility is less in continuous reaction
and modification of process is difficult
5) Large quantity production
6) Each portion specific concentration of
starting material and product
7) Mixing and mass transfer is very efficient
and effective
8) Control of temperature in flow process
achieved accurately due to high surface area
to volume ratio

9. Flow reactors types :
 Plug flow reactors
 Column reactors
 Gas reactors
 Reactors for slurries
 Photochemical flow reactors
 Trickle bed reactors
TYPES:
 TYPE I – no catalyst
 TYPE II- supported reagent
 TYPE III- homogeneous catalyst
 TYPE IV- supported catalyst

10. ADVANTAGES :
• Improved Safety: Better control over reaction conditions, reduces the likelihood of accidental exposure
to hazardous materials.
• Higher Efficiency: The continuous flow of reactants and products allows for better control over
reaction parameters like temperature ,pressure, concentration of reactant and product, easier separation
of the products.
• Scalability: Flow chemistry is easily scalable, meaning that a small reaction can be easily scaled up to a
larger industrial-scale production.
• Faster Reactions: Flow chemistry can result in faster reaction times and more rapid product formation,
which can save time and resources.
• Reduced Waste: The efficient use of reagents and catalysts, fewer byproducts are produced, reducing
waste and minimizing the need for purification steps.
• Improve product quality: Purity, quality control and check by sensors ,maximum yield and minimum
impurities.
• Broader Scope of Chemistry: Flow chemistry can be used for a wider range of chemical reactions than
traditional batch reactions, including reactions that are difficult to perform or unstable under batch
reaction conditions some reactive chemicals and hazardous chemicals

11. SYNTHETIC APPLICATION:
• Continuous flow synthesis of Diphenhydramine HCl
• Continuous flow synthesis of Ibuprofen
• Continuous flow synthesis of Telmisartan

12. CONCLUSION:
• A reactor is a vessel or system in which a chemical reaction takes place.
• Flow chemistry, also known as continuous-flow chemistry or microreactor
technology, is a type of chemical synthesis that involves the use of continuous-
flow reactors instead of traditional batch reactors.
• Working: feeding, mixing, reaction, collection, monitoring and control follow
reaction mechanism.
• Batch reactors and continuous flow reactors.
• Types of reactors like plug flow and column reactor.
• Advantages like improved control over production, enhance safety and
product quality.
• Synthetic applications,ibuprofen,telmisartan, diphenhydramine hydrochloride.

13. REFRENCES:
Wiles C, Watts P. Continuous flow reactors: a perspective. Green Chemistry. 2012;14(1):38-54.
Wiles C, Watts P. Continuous flow reactors, a tool for the modern synthetic chemist. European
journal of organic chemistry. 2008 Apr;2008(10):1655-71.
Murata K, Hirano Y, Sakata Y, Uddin MA. Basic study on a continuous flow reactor for thermal
degradation of polymers. Journal of Analytical and Applied Pyrolysis. 2002 Oct 1;65(1):71-90.
Baumann M, Baxendale IR, Ley SV, Nikbin N, Smith CD, Tierney JP. A modular flow reactor for
performing Curtius rearrangements as a continuous flow process. Organic & Biomolecular
Chemistry. 2008;6(9):1577-86.
Irfan M, Glasnov TN, Kappe CO. Heterogeneous catalytic hydrogenation reactions in
continuous‐flow reactors. ChemSusChem. 2011 Mar 21;4(3):300-16.