Macro-microreactor-Based Process Intensification for Achievement of High-Mixing-Performance, Low-Pressure-Drop, and High-Throughput Liquid-Liquid Homogeneous Chemical Processes

Microreactors provide an enhanced mixing performance but suffer from low throughput. This work proposed a macro-microreactor with designed internals to achieve both process intensification and scale-up for the liquid-liquid homogeneous chemical processes. Numerical simulations utilizing computational fluid dynamics were conducted to investigate the fluid mechanics and the properties of mixing of a macro-microreactor (feature size >2000 μm). Experimental validation using the Villermaux-Dushman reaction demonstrated that this easily fabricated macro-microreactor with optimized helical-shaped internal achieved a comparable mixing performance, lower pressure drop, and higher throughput compared to a typical microreactor with a smaller feature size (1000 μm). The macro-microreactor would find more applications in industrial liquid-liquid homogeneous chemical processes.