The translation from batch to continuous processing
appears to be straightforward, although more knowledge
(e.g., on the internal temperature of tubular reactor R1) is
required to allow a rational prediction. However, a longer
residence time is not feasible with the current setup, while
complete conversion demands a very long mean residence
time (∼1 h). Presumably, this might be circumvented by
the addition of a suitable catalyst. Nevertheless, the batch-
loop operation allows high conversions in a short time
with a proper temperature control.
mixture; see each specific procedure. Tetradecane was
used as an internal standard.
(R)-1-Phenylethyl Acetate. A 1 L round-bottomed flask
was charged with a solution of (R,S)-1-phenylethanol (48
g, 0.4 mol) and vinyl acetate (172.2 g, 2 mol) in toluene
(700 L). The reaction mixture was circulated via a
membrane pump with a flow of 175 mL · min-1 through
the continuous-flow reactor of Milestone equipped with
a Weflon stirrer and was heated to 70 °C (T1). On top of
the reactor cooling was applied to maintain T2 below 30
°C. Subsequently, Novozym 435 (5.0 g) was added to the
flask (experiment A) or to the tubular reactor (experiment
B, including a temporary hold of the flow), and the set
temperature was maintained for a period of 180 min. The
total reaction volume was 940 mL. Average power
usage during reaction was 226 W (experiment A) and
236 W (experiment B). During the reaction, aliquots
were taken from the liquid phase and measured by GC.
After 180 min the mixture was collected, resampled, and
cooled.
6. Concluding Remarks
The transfer of microwave energy into heat, directly
or indirectly via the Weflon blades, allows the use of
several reaction mixtures in terms of polarity or loss
tangent. The combination of stirring and heating gives rise
to an efficient energy transfer. The residence time
distribution of the CFR (Milestone FlowSynth) with a
single pass results in a performance equivalent to that of
a series of three equally sized CSTRs.
Laurydone [Experiment A]. A double-walled reactor was
charged with (S)-pyroglutamic acid (69.1 g, 0.54 mol) and
n-decanol (622 g, 3.93 mol). The reaction mixture was circulated
via a membrane pump with a flow rate of 115 mL ·min-1
through the continuous-flow reactor of Milestone equipped with
a Weflon stirrer and was heated to 150 °C (T1). On top of the
reactor no cooling was applied. The double-walled reactor was
thermostatic at 60 °C at the walls. The reaction time was 140
min, and the total reaction volume was 700 mL. The average
power usage during reaction was 294 W. During the reaction,
aliquots (∼50 mg) were taken, quenched with dichloromethane
(3 mL), and measured by 1H NMR (CD3OD, 200 MHz) typical
signals δ (ppm) 4.14 (t, 2H, CH2-OCO, product), 3.53 (t, 2H,
CH2-OH, decanol).
Laurydone [Experiment B]. A double-walled reactor was
charged with (S)-pyroglutamic acid (69.0 g, 0.53 mol) and
n-decanol (622 g, 3.93 mol). The reaction mixture was circulated
via a gear pump with a flow rate of 343 mL ·min-1 through
the continuous-flow reactor of Milestone equipped with a
Weflon stirrer and was heated to 150 °C (T1). On top of the
reactor no cooling was applied. The double-walled reactor was
not thermostatic at the walls. The reaction time was 178 min,
and the total reaction volume was 700 mL. The average power
usage during reaction was 444 W. During the reaction, aliquots
(∼50 mg) were taken, quenched with dichloromethane (3 mL),
and measured by 1H NMR (CD3OD, 200 MHz) typical signals
δ (ppm) 4.14 (t, 2H, CH2-OCO, product), 3.53 (t, 2H,
CH2-OH, decanol).
Recalculating the operational costs is necessary to decide
whether microwave heating is still beneficial if larger production
scales are planned. In view of the higher operational costs and
apart from the safety issue the chances to incorporate microwave
heating as a competitive technique seem to decrease with
increasing scale.
As demonstrated in our experiments, plugging as a
result of solid reactants/products is a point of attention in
further process design for solid-liquid organic reactions.
Redesigning the equipment, involving Teflon-coating and
thermostatic tracing, may overcome fouling and plugging
in the present study. Also redesigning the present Flow-
Synth setup allows coping with issues such as solids and
slurry handling.
From a technical point of view scaling up heteroge-
neous reactions by microwave irradiation is feasible. Not
only is it possible to rapidly heat the reaction mixture,
but the experimentally observed batch data of the
conversion-time history can also be used for process
design. Direct temperature control and the opportunity to
quench the reaction easily are highly advantageous. High
production rates can be achieved for batch-wise operation
by numbering up the microwave-heated reactor units.
7. Experimental Section
The continuous-flow reactor was supplied by Milestone srl,
Italy. The tubular reactor could either be equipped with a Teflon
or a Weflon stirrer. The original setup included a membrane
pump of Alldos GmbH (now known under the name Grundfos);
type 281-9, 6-1004; 100 bar; 50 Hz. The gear pump was
supplied by the manufacturer Gather Industries, type 320;
PM8060 L.
General Methods. Chiral gas chromatography (GC) was
performed on a Shimadzu 6C-17A GC equipped with a
Chrompack Chirasil-DEX CG (DF ) 0.25) column, and
a FID. Injection temperature was set at 250 °C and the
detection temperature at 300 °C. Temperature programs
were used to optimize the analysis for each reaction
O-Acetyl Salicylic Acid. A round-bottomed flask was
charged with salicylic acid (207 g, 1.5 mol), acetic acid (1228
g, 1.12 L), and acetic anhydride (307 g, 3.0 mol). After 15 min
of mixing (almost complete dissolution), the reaction mixture
was pumped via a membrane pump with a flow rate of 27
mL·min-1 through the continuous-flow reactor of Milestone
equipped with a Weflon stirrer and was heated to 120 °C (T1).
On top of the reactor, cooling was applied. The residence time
was 6.5 min. The average power usage during reaction was
253 W. During the run, the reaction mixture was collected in
360
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Vol. 14, No. 2, 2010 / Organic Process Research & Development