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BIO-GO-For-Production is a Large Scale Collaborative Research Project that aims to achieve a step change in the application of nanocatalysis to sustainable energy production through an integrated, coherent and holistic approach utilizing novel heterogeneous nanoparticulate catalysts in fuel syntheses. BIO-GO researches and develops advanced nanocatalysts, which are allied with advanced reactor concepts to realise modular, highly efficient, integrated processes for the production of fuels from renewable bio-oils and biogas. Principal objectives are to develop new designs, preparation routes and methods of coating nanocatalysts on innovative micro-structured reactor designs, enabling compact, integrated catalytic reactor systems that exploit fully the special properties of nanocatalysts to improve process efficiency through intensification. An important aim is to reduce the dependence on precious metals and rare earths. Catalyst development is underpinned by modelling, kinetic and in-situ studies, and is validated by extended laboratory runs of biogas and bio-oil reforming, methanol synthesis and gasoline production to benchmark performance against current commercial catalysts. The 4-year project culminates in two verification steps: (a) a 6 month continuous pilot scale catalyst production run to demonstrate scaled up manufacturing potential for fast industrialisation (b) the integration at miniplant scale of the complete integrated process to gasoline production starting from bio-oil and bio-gas feedstocks. A cost evaluation will be carried out on the catalyst production while LCA will be undertaken to analyse environmental impacts across the whole chain. BIO-GO brings together a world class multi-disciplinary team from 15 organisations to carry out the ambitious project, the results of which will have substantial strategic, economic and environmental impacts on the EU petrochemicals industry and on the increasing use of renewable feedstock for energy.

Viviano M.,Christian Doppler Laboratory | Viviano M.,University of Salerno | Glasnov T.N.,Christian Doppler Laboratory | Reichart B.,Christian Doppler Laboratory | And 2 more authors.
Organic Process Research and Development

Three different continuous flow strategies for the generation of important 4-aryl-2-butanone derivatives including the anti-inflammatory drug nabumetone [4-(6-methoxy-2-naphthalenyl)-2-butanone] and the aroma compounds raspberry ketone [4-(4-hydroxyphenyl)-2-butanone] and its methyl ether [4-(4-methoxyphenyl)-2-butanone] were evaluated. All three protocols involve the initial preparation of the corresponding 4-aryl-3-buten-2-ones via Mizoroki-Heck, Wittig, or aldol strategies, which is then followed by selective hydrogenation of the C=C double bond to the desired 4-aryl-2-butanones. The synthetic routes to 4-aryl-3-buten-2-ones were first optimized/intensified on small scale to reaction times of 1-10 min using batch microwave heating technology and then translated to a scalable continuous flow process employing commercially available stainless steel capillary tube reactors. For the synthesis of 4-(4-methoxyphenyl)-3-buten-2-one a further scale-up using a custom-built mesofluidic mini-plant flow system capable of processing several liters per hour was designed to further expand the scale of the process. The final hydrogenation step was performed using a fixed-bed continuous flow hydrogenator employing Ra/Ni as a catalyst. © 2011 American Chemical Society. Source

Kirschneck D.,Microinnova Engineering GmbH
Chemical Engineering and Technology

An innovative concept for the characterization of situations or problems (drivers) where the application of continuous flow processing, microreactor and/or other intensification technologies lead to the desired solutions is presented. An overview of techniques and equipment (tools) currently available for developing intensified processes is given as well as some examples of how they can be implemented in the engineering of chemical plants in kilo-lab, pilot-, and full-size manufacturing scale. These drivers and tools are described and depicted by easy-to-understand icons, and strategies for the development of continuous processes are explained. Short summaries of three different case studies demonstrate the economic advantages and potentials of intensified flow processing in manufacturing scale. Finally, the current approach to avoid inflexibility of systems operated in continuous mode is reported and how pilot and manufacturing plants can be realized with a special focus on modularity and multi-purpose functionality. © 2013 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim. Source

This work presents a new innovative concept, how basic manufacturing needs of small and medium scale manufacturing tasks can be moved to a higher level of efficiency. The basic idea of the concept is to combine the long time known performance of continuous processing with the flexibility of today's common batch synthesis. The concept uses a modularized continuous plant concept, where the needed flexibility is provided by first rearrangement of the processing s modules and second modularity within each module to adjust it according to the needs of each chemical reaction. This ? gives the possibility to reach a continuous processing performance by means of a flexible multi purpose plant. Source

Besenhard M.O.,Research Center Pharmaceutical Engineering Gmb | Besenhard M.O.,Siemens AG | Thurnberger A.,Research Center Pharmaceutical Engineering Gmb | Thurnberger A.,Microinnova Engineering GmbH | And 5 more authors.
International Journal of Pharmaceutics

We present a proof-of-concept study of a continuous coating process of single API crystals in a tubular reactor using coacervation as a microencapsulation technique. Continuous API crystal coating can have several advantages, as in a single step (following crystallization) individual crystals can be prepared with a functional coating, either to change the release behavior, to protect the API from gastric juice or to modify the surface energetics of the API (i.e., to tailor the hydrophobic/hydrophilic characteristics, flowability or agglomeration tendency, etc.). The coating process was developed for the microencapsulation of a lipophilic core material (ibuprofen crystals of 20 μm- to 100 μm-size), with either hypromellose phthalate (HPMCP) or Eudragit L100-55. The core material was suspended in an aqueous solution containing one of these enteric polymers, fed into the tubing and mixed continuously with a sodium sulfate solution as an antisolvent to induce coacervation. A subsequent temperature treatment was applied to optimize the microencapsulation of crystals via the polymer-rich coacervate phase. Cross-linking of the coating shell was achieved by mixing the processed material with an acidic solution (pH < 3). Flow rates, temperature profiles and polymer-to-antisolvent ratios had to be tightly controlled to avoid excessive aggregation, leading to pipe plugging. This work demonstrates the potential of a tubular reactor design for continuous coating applications and is the basis for future work, combining continuous crystallization and coating. © 2014 Elsevier B.V. Source

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