Microreactors (Expert)

How are Microreactors Made?

Due to the small size of microreactors, they must be made with high precision. Typically, microreactors are made by etching channels on a substrate such as metal, glass, or other type of ceramic. These channels are made using such techniques as lithographic (photolithography), electrical discharge machinery, or laser micromachining.

One common type of microreactor is made up of a 'sandwich' of thin metal sheet or plates with microchannels or fluid channels that have been etched into both sides. The average size of a single unit is approximately 1½ in. by 2½ in. by ¼ in. with channel widths and wall thickness of 200-300 mum. The reactions occur in every other layer and the other layers are used for heat-exchange fluid flows.

Can Microreactors be used Industrially?

Currently, there are no microreactors in commercial use. However, researchers are studying how to implement microreactors into the chemical industry. One possibility would be to run tens of thousands of the tiny reactors in parallel creating a continuous flow microreactor. This would allow a network of the reactors to behave like a conventional, large-scale reactor, but still have the specialized capabilities of the microreactor.

Another design currently under research is a system in which thin plates, with a wall thickness of 200-300 micrometers, are stacked on top of each other like lego blocks. Fluid passages are molded in between the plates, which allows for both chemical reactant and heat transfer flow. While both of these designs are in the development stages, researchers believe that they have the potential for industrial use.

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