Micro Process Server. Standard Specifications. Hitachi Microreactor System

Transcription

1 Standard Specifications External dimensions Weight 460 ( W ) 451 ( D ) 536 ( H ) mm ( main unit ) Approx. 35 kg ( main unit ) Mixing//Emulsification System For R&D and Small-Volume Production ( MPS-200 ) For Large-Volume Production ( System Example ) 1,600 ( W ) 1,900 ( D ) 1,300 ( H ) mm ( main unit ) Approx. 600 kg ( main unit ) Concentration System For Large-Volume Production ( System Example ) 900 ( W ) 3,400 ( D ) 2,500 ( H ) mm Approx. 1,000 kg ( main unit ) Hitachi System Micro Process Server Provides uniform and highly efficient mixing, reaction, emulsification and concentration of liquids in a micro space Liquid feed system Electronically controlled syringe pump for continuous feeding Continuous diaphragm pump Roller tube pump Capacity 30 ml/min ( can be set between 0.5 and 400 ml/min ) 120 l/h max. 36 l/h max. ( for a concentration rate of seven times ) Settable temperature range -20 to 120 ( at the surface of the temperature controlling plate ) 5 to 80 ( preset temperature ) Room temp.10 to 80 ( preset temperature for hot water ) Number of microreactors mounted material 2 SUS316, Hastelloy, PEEK 10 3 ( available up to 5 ) SUS316 Utility Power source ( AC 100V ) Power source ( AC 200V ) Power source ( AC 200V ), Cooling water, Steam, Compressed air, Water for a water wing pump For specifications other than the above, please consult us. Safety Precautions About the Liquid Handled by the MPS Systems The liquid fed by the systems shown in this catalog must be a kind of liquid that does not corrode and/or deteriorate the parts of the systems exposed to the liquid.( Otherwise, personal injury might be caused by leaks, electric shock or the liquid itself. The material exposed to the liquid shall conform to the contract specifications. ) About the Installation Site The MPS systems must be installed indoors. Do not use the systems at a place exposed to moisture, including rain, steam, condensation and/or chemicals. ( This may cause fire, electric shock, rust in the parts of the systems or shortened service life. ) Do not use the systems at a place close to explosives, flammable gases (e.g., acetylene, propane), organic solvents, explosive dust and fire. ( These may cause fire or accidents. For explosion-proof systems, refer to the contract specifications. ) Do not use the systems at a place exposed to ammonia, acid, salt and/or corrosive gases such as sulfur dioxide and chlorine gas. ( These may cause rust, shortened service life or mechanical damage. ) About the Use of the MPS Systems Before using the systems, familiarize yourself with their instruction manuals to ensure proper use. Do not retrofit, dismantle and reassemble the systems. ( These may cause nipping, electric shock or burns, resulting in the failure of the systems. For microreactors, conform to the respective instruction manuals. ) Head Office : Rise Arena Bldg., 5-2, Higashi- Ikebukuro 4-chome, Toshima-ku, Tokyo Phone : Facsimile : International Sales Division : Rise Arena Bldg., 5-2, Higashi- Ikebukuro 4-chome, Toshima-ku, Tokyo Phone : Facsimile : For more information, contact: Due to continued improvement efforts, the content of this catalog is subject to change without notice. Guarantee of performance is in accordance with contract specifications.

2 A device for performing mixing, reaction, emulsification and concentration in a micro space Faster transition to mass ion is achieved by using a parallel array of laboratory used microreactors. What is a microreactor It is neither a flask nor a batch reactor It is a device for performing chemical reactions in a micron-order space. Concentration system for large-volume ion Mixing, reaction and emulsification system for large-volume ion System for research and development and small-volume ion Micro Process Server is a system for research and development or mass ion with chip-shaped microreactors. The Micro Process Server enables reactions under accurate control in a micro space thereby achieving highly efficient mixing, reaction, emulsification and concentration in an extensive range of applications such as chemical s, pharmaceuticals, foods, cosmetics, electronic materials, catalyst materials and paint. Micro Process Server is a registered trademark in Japan of Hitachi Plant Technologies, Ltd. 1 2

3 Benefits of the Micro Process Server The Micro Process Server (MPS) enables highly efficient mixing, reaction, emulsification or concentration tailored to the needs of various applications, thereby reducing the time to launch mass ion. Mixing Enables mixing/reaction with higher stability, homogeneity and yield Concentration Enhances the efficiency of concentration by thinnerliquid films Excellent temperature control enhances the stability of reaction temperatures. Improves the yield of reaction Liquid film thickness of a micron order Accommodates heat-sensitive materials Ensures cleanability essential for food equipment The large heat transfer area relative to the volume of liquid enables fast heating and cooling, achieving stable temperature control without being subject to the heat of reaction. Temperature control plate for a microreactor Surface temperature : can be controlled between -20 and +120 Temperature Heating enables high-speed heating and cooling Heating Conventional Cooling method Cooling Image of Temperature Control ( Example of the MPS system for R&D/small-volume ion ) Produces nanoparticles The ability of homogeneous mixing produces nanoparticles of uniform diameter. Time Photo of nanoparticles The reduction in by-s contributes to the more effective utilization of raw materials and waste reduction. Bromination Nitration Ester reduction Formula 1-substitution 1-substitution 2-substitution 2-substitution 1-substitution 2-substitution Conventional Batch Method Yield Yield Improvement When producing concentrated liquid by evaporating the water within, a rotary mechanism, such as a centrifugal film evaporator, was conventionally used to obtain liquid films. The microreactor, however, uses built-in micro flow paths to produce liquid films. This enables the creation of liquid films of a micron-order thickness, increasing the heat transfer area. Rate of concentration (times) Flow rate of the original liquid (ml/min) The original liquid is heated via hot water at a temperature between 50 and 70 by vacuumizing the inside of the system to lower the boiling point of the liquid. This inhibits deterioration of the heat-sensitive active ingredients. Relationship between Throughput and Rate of Concentration (Per one microreactor for concentration, Original liquid: black vinegar) Black vinegar Acerola juice Dairy The introduction of microreactors carefully designed for cleanability as well as sanitary plumbing equipment enables automatic stationary cleaning. Emulsification Produces micron-order particles of uniform diameter Reduces the lead time to Mass Production Conventional scale-up approach Produces emulsified droplets of uniform diameter Uniform emulsified droplets are produced by the shearing force, which arises when the flows Water of water are applied. Achieving emulsification under a low pressure of 0.5 MPa constrains a rise in temperature, Oil preventing heat-induced deterioration. Water Emulsified liquid Produces emulsified droplets of uniform diameter Emulsified droplets Percentage of droplets (%) Droplet diameter (µm) Distribution of droplet diameters Scale up R&D Micro Process Server Numbering up R&D Pilot plant Mass ion plant Scale up Mass ion plant (batch processing) Reducing the steps to mass ion Steps to mass ion are reduced through the numbering up approach, that is, using a parallel array of the microreactors developed in the R&D stage. 3 4

4 The MPS for R&D and Small-Volume Production GUI Screen Initial Setup Screen Improves user-friendliness on the graphic user interface (GUI) screen based on the HPT s accumulated expertise in process developments. Pump state indicator Mixing Emulsification Syringe size selection Features/Configuration This system is available for an extensive range of microreactor applications, such as the mixing, reaction and emulsification processes. Using two microreactors (standard specification) enables a two-step reaction. The flow rate can be set between 0.25 to 100 ml/min. (The onboard syringe size is selectable from among 1, 2.5, 5, 10 and 25 ml.) The optional auxiliary pump unit accommodates more than the two-step mixing or reaction processes. Can be set from 1 to 25ml Mode selection Selects the mode of operation according to the system application. Before activation System in action Provides an at-a-glance view of the pumps in use and the flow of liquids Return to the default Resets the last settings to the default before starting an experiment Temperature setting Enables detailed temperature adjustments for heating and cooling Example of System Configuration (for two-step/multistep reaction) Optional Liquid D Liquid C Liquid B Liquid A Extension using the auxiliary pump unit Manual Feed Mode This mode puts the entire operation of the system, including the feed of liquids and the switching of valves, under manual control. Multistep Two-Step The behavior of pumps, such as the flow volume and flow rate of liquid can be set individually. Pump Unit The double syringe configuration enables a continuous feed of liquids. The interlock function* enhances safety when the system is in continuous operation. *The interlock function Monitors the system s pressure and temperature and stops the system automatically when they exceed preset values; and Monitors the system for abnormal conditions, such as clogged feed lines, and stops the system automatically. Auxiliary Pump Unit Example of System Configuration (for a continuous feed using double syringes) A continuous feed is attained by the double syringe pair Programmed Feed Mode This mode records a sequence of manual procedures in advance and puts the system in automatic operation according to the sequence. Continuous Feed Mode This mode puts the system in the continuous feed mode using the double syringe configuration. Pump Motion Setup Window You can set the flow volume and flow rate of liquid and the retention time of liquid, as well as repeat a sequence of procedures as many times as required. A large volume of liquid can be mixed and reacted under automatic monitoring at all times. (The flow volume of liquid can be set up to 300,000 ml.) 5 6

5 The MPS Mixing, and Emulsification System for Large-Volume Production The MPS Concentration System for Large-Volume Production Mixing Emulsification Concentration Features/Configuration Features/Configuration A two-step reaction can be achieved using the same microreactors as used for the R&D/small-volume ion system. A combination of microreactors can be freely set, such as five for the first step and five for the second. Touch panel operation is adopted. While in automatic operation, the system is operated automatically according to preset values, including the temperature and flow rate of raw materials. On the screen, you can see the values measured by the onboard sensors (e.g., pressure, temperature). The system automatically stops in the case of an abnormal condition. The main unit of the system can be constructed to be explosion proof. Example of System Configuration (explosion-proof specifications) The number of concentration microreactors to be mounted can be selected to meet your desired throughput. Touch panel operation is adopted. Your desired concentration rate can be achieved by adjusting the flow rate of raw materials. While the system is in automatic operation, you can see the values measured by the onboard sensors (e.g., pressure, temperature, flow rate of heating or cooling water). The system automatically stops in the case of an abnormal condition. The system is available for two-step concentration (optional specifications). As an example, in order to increase the flow volume of the raw material (throughput), you can increase the flow rate of the raw material and obtain low-concentration at the first step, then re-concentrate it to obtain the desired rate of concentration at the second step. Example of System Configuration (three microreactors mounted) Material Tank C Material Tank B Product Tank Steam Raw Material Tank Material Tank A Electricity Hot Water Circulation Unit System Main Unit Control Board Steam Drain Air Cooling Water Electricity Water System Main Unit Explosion-Proof Area Safety Area Circulating Temperature- Controlled Bath Concentrated Product Tank Distilled Liquid Tank Discharged Water Vacuum Pump 7 8

6 Total Support With the accumulated engineering expertise as a plant manufacturer, we provide total support from R&D, plant operation for mass ion to after-sales services. Flow from R&D to mass ion for your new process Customer Needs Process Selected MPS for R&D and small-volume ion introduced Experiments Specifications determined / System constructed Launch of the MPS System for Mass Production Desired Processes Proposed by HPT Process Analysis Reactor Custom Designing Designv / Manufacturing / Examination / Installation / Commissioning After-Sales Services Based on considerable experience in process development, we propose various kinds of processes that can best meet customer requirements. A joint verification test with customer-supplied reagents can be conducted at our demonstration room. With the HPT s proprietary fluid simulation and microfabrication techniques, the best fluid path structure is designed and fabricated. HPT s engineering and manufacturing expertise and onsite handling capacities are fully utilized. On-call and periodic onsite maintenance services are provided. Abundant Experience of Experiments on Various Kinds of Processes Demonstration Room Facilities Proprietary Fluid Simulation Technique After-Sales Services As of September 2009, more than 50 R&D results have been externally released and more than 40 patents have been applied for by researchers at Hitachi, Ltd., and HPT researchers and engineers. HPT has proposed desired processes and conducted demonstration experiments under nondisclosure agreements for more than 50 corporate clients. Major R&D Results Externally Presented Development of a pilot plant using the numbering up of microreactors, 9th International Conference on Microreaction Technology2006 Chemical process innovation by using a microreactor, 12th Asia Pacific Confederation of Chemical Engineers2008 Computational Fluid Dynamics of Water-in-oil Emulsion using, International Symposium on Micro Chemical Process and Synthesis2008 Yield Improvement in Consecutive using, International Symposium on Micro Chemical Process and Synthesis2008 Black Vinegar Condensing Plant With High-Speed Microevaporators, MicroTAS(2009) This room has the following MPS systems for demonstration and facilities for the evaluation of s. a Micro Process Server (MPS) Two R&D and small-volume ion systems One large-volume ion system for mixing, reaction and emulsification (10 micro reactors mounted; explosion-proof specifications) One large-volume ion system for concentration (Five micro reactors mounted) Others, including systems for element tests b Analytical/Measuring Equipment Liquid chromatography, Gas chromatography, Laser diffraction particle size analyzer, Digital microscope, etc. With its proprietary fluid simulation technique, HPT is able to clarify process problems and suggest possible solutions for process improvement. Example of an Analysis of Fluid Path Structures Fluid Path Under its annual maintenance agreement with clients, HPT offers maintenance services that include the following. 1 On-call maintenance Upon receiving a call to report a problem with the system in operation, our maintenance personnel will promptly visit the client and take appropriate measures. 2 Regular onsite maintenance Our maintenance personnel visits the client on a regular basis to check the status of system operation, provide advice on operation, hear any requests from the client and provide any other services. 9 10