Innovation Drives Green Growth - Industrial Green · PDF fileInnovation Drives Green Growth: Advanced Flow Reactor Technology - Industrial Production Made Real Agenda ... Corning Incorporated

Innovation Drives Green Growth:Advanced Flow Reactor Technology -Industrial Production Made Real

Agenda AFR™ Technology & Products AFR™-Production Made Real

AFRTM Case Studies Concluding Remarks

C K SethiaManager Sales – AFR India

April 28, 2015 – Green Chemistry – Hyderabad, India

Advanced-Flow™ Reactor Technologies 2.

© 2015 Corning Incorporated ..

Corning Incorporated Founded: 1851

Headquarters: Corning, New York

Employees: ~34,000 worldwide

2014 Sales: $10.2B

US Fortune 500 Rank (2014): 343

Corning is the world leader inspecialty glass and ceramics.

Corning Reactor Technologies: Program started: 2002

Business Headquarters: Avon, France

Provide innovative Corning® Advanced-Flow™ Reactor products and full engineeringservices for

Flow Chemical Process Development Flow Chemical Industrial Productionfor Pharma Chemicals

Fine Chemicals Specialty Chemicals Base Chemicals

Corning New York, USACorning European TechnologyCenter (CETC), Avon, France



AFR™ Patented Heart-Cell Designsoffer fast mixing & superior heat exchange (1000X enhancement)

Mixing of Two Liquid PhasesLiquid 1: BlueLiquid 2: YellowMixture: Green

HE Layer

Reactants1, 2 (in) Product (out)HE fluid outHE fluid in

HE Layer

Reaction Layer

HE area: 2500 m2/m3

HE area： 2500m2/m3

U×(S/V) 1 MW/m3.K

Corning® Specialty Glass



AFR™ Reactor Offers Superior G-L, L-L Mass Transfer Performancewith Much Lower Energy Consumption (or Pressure-Drops)

Corning AFR

Volu

met

ric

mas

s tr

ansf

er c

oeff

icie

nt

Volu

met

ric

mas

s tr

ansf

er c

oeff

icie

nt

Bioreactor

Gas-inducing impellersMechanically agitated contactor

Bubble column

Static mixer

Agitated contactor

MIT-Klavs F. Jensen Group fundamental study of Corning G1 fluidic module,published a series of results (2012-2013）

Corning AFR

Batch reactor

Capillary microchannel

L-L System: Ind. Eng. Chem. Res., 2012, 51 (50), pp 16251–16262 G-L System: Ind. Eng. Chem. Res., 2013, 52 (26), pp 8996–9010



Consistent mixing and mass transfer from lab toproduction at same residence time

LFR 5 t/y

G1, 80 t/yG2, 250 t/y

G3, 1000 t/y

G4, 2000 t/y



Replacing batch reactor processes with “continuous-flow”reactor processes: Significant Improvement in Safety



AFR: Revolutionary Improvement vs. Batch

1000 X HE Improvement1000 X HE Improvement100 X MixingImprovement100 X MixingImprovement1/1000 X Batch ReactorVolume1/1000 X Batch ReactorVolumeSeamless Scaleup fromLab to ProductionSeamless Scaleup fromLab to Production

25% ReadilyConvertible

25% Convertiblewith efforts

25% withHybrid Approach

25%Not Convertible!

Not 100% reactions fit to AFR Continue requiring innovative process

development Chemists, ChE, MechE work together



AFR Provides Comprehensive Solutionsfrom Lab to Production

G1

G2 SiC

G3

G4 SiC Large productionFlow: ~300 kg/hrAnnual: 2000 t/y

Large productionFlow: ~150 kg/hrAnnual: 1000 t/y

Lab flow-chemistryR&D (high PH/high T,HF)

Small-productionFlow: 15-35 kg/hr(high PH/high T, HF)

Medium productionFlow: ~35kg/hrAnnual: 250 t/y

Lab flow-chemistryR&D

Kilo-lab productionFlow: 1.5-15 kg/hr

Small productionFlow: ~15 kg/hrAnnual: 80 t/y

LF Lab flow-chemistryR&D

Kilo-lab productionFlow: 0.1-0.6 kg/hrAnnual: 5 t/y



Corning AFR™ G1 Process Development System PlatformChiller for temperatureControl:-20 to 200oC, 2.5 bar

Corning AFR™ ReactorsOperating Inlet pressure up to 18bar

Dosing Lines (20 bar)(S.S. ormetal-free pump-heads)

A BPAFR™ G1 Process Development Platform



AFR™ G2 SiC Offers Special Solutions for Highly Causticat High Temperature, HF Involved Applications

Internal volume: 28mL per plate

You can open the reactive plates!

Operating conditions：Temperature = -10 ~ 200C; Inlet Pressure = 0 ~ 18 bars; Flow rate = 50 ~ 500 ml/min



Corning Launched AFR™ G1 Photo Reactor• An engineered reactor with all of the

benefits from the existing G1 reactor(good mixing, good temperaturemanagement, etc)

• Plus:– Good control of the light source

• Position of the LED guaranteeshomogenous illumination

• LED temperature controlguarantees long lifetime

– Double illumination guarantees amore efficient use of the light

– Choice of wavelength• 365 nm, 405 nm, etc.

– Light intensity is tunable

G1-5FM

LED Lighting Device



AFR™ technology & manufacturing have received manycertificates, and awards in Europe and Asia

AFR helped ChangzhouUniversity winNational Grand Award“Challenge Award”

TÜV PED QualityCertificate (G4 SiC)

China SELO A4 (SiC) EU ATEX II 2 G c IIC

T4 Certificate (G1, G3)Certificates

FDA Certificates forcompliances

ISO 14001 …

TÜV PED QualityCertificate (G4 SiC)

China SELO A4 (SiC) EU ATEX II 2 G c IIC

T4 Certificate (G1, G3)Certificates

FDA Certificates forcompliances

ISO 14001 …

Received 2013 NationalInnovation Award by ChinaPetroleum & ChemicalIndustry Federation CPCIF



Corning® AFR™ Reactor Technology is committed to providing globalapplication engineering and commercial support

ChinaIndia

Commercial OfficeApplication Lab & Engineering Team

AsiaEuropeNA

USA

Certified Application LabAFR Demonstration Lab

France



Hydrogenation with Pd/C catalyst:We can dose the slurry (Pd/C G1+solvent or raw materials) into G1 usingdiaphragm pump, and clean it out with solvent as shown

Catalyst size < 200 µm, typically 20-100 µm

diaphragm pumpAFR G1 fluidic module feeding

with Pd/C + solvent



Selective Hydrogenation of Slurry in Corning® AFR98%+ conversion & selectivity (impurity profiles within spec.)

• highly exothermic (>400 kJ/mol)• ~30 µm catalyst in slurry• significant catalyst reduction

This image cannot currently be displayed.

Excellent G/L Mixing

Ref: Chemistry Today 27(6),Nov-Dec (2009)

30C 140C

0.1%0.4%

45%wt35%wt

90s10h

Batch AFR



-100.00

-80.00

-60.00

-40.00

-20.00

0.00 20.00 40.00 60.00 80.00 100.00

isobutene

STBE Yield

AcetoneExcess

Time

AFRBatch

Green Process: Glycerine to Fuel Additives in Corning® AFRSuccessful feasibility demonstration for ~1000 mt/y industrial production

Ref: Chemistry Today – submitted (2010)

• 10% biofuels for transports by 2020 in EU

• 20 millions tons biodiesel capacity in 2009 (EU)

• 10 tons biodiesel => 1 ton Glycerine (by-product)

Convert Glycerine to STBE(Solketal TertButyl Ether) via Solketal

11-12 kg/hr STBE (90 tons/Year)

Short process development cycle:~4 months

acetone isobutent

STBESolkertalGlycerine

4 equivalents

< 2 min6-10h

Batch AFR

10-12 equivalents

~80% ~85%

Ratio = 1Ratio = 2

SolventReduction

SolventReduction



Carbonyl hydrogenation to hydroxyl (1)

R C

O

R C OH´ß »¯ ¼Á

Catalyst Activity vs. # of Catalyst RecyclesConversion vs. reaction time

Con

vers

ion

Cat

alys

t Act

ivity

Batch HydrogenationConversion

AFR HydrogenationConversion

AFR Cat Activity

Batch Cat Activity



Carbonyl hydrogenation to hydroxyl (2)

R C

O

R C OH´ß »¯ ¼Á

Number of expt.

Yiel

d

AFR HydrogenationYield

Batch HydrogenationYield

Corning AFR delivered better and much stable yield



Low Temperature ApplicationsEnergy saving and/or better yield (DCM-B-Pin)

Hans-Rudolf Marti et al, “1st Symposium on Continuous FlowReactor Technology for Industrial Applications” (October 12, 2009) Batch AFR AFR

Feed A: DCM +Pinacolato-isopropylborate

Feed B: LDA in THF



Chlorination using AFR

R1 CH2 R2 R1Cl2 CH R2

Cl

+ R1

Cl

C R2

Cl

(A)

(B) (C)

Targeted product: B Batch: -10℃with fast reaction rate, high heat release, temperature

rises rapidly By-product C is formed if more Cl2 is fed By-product C is explosive potential, unstable Product B is unstable, hard to control the reaction ending point



Chlorination Results (1): Batch vs. AFR

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

-10 -8 -6 -4 -2 0 2 4 6 8 10

收率

反应温度t/℃

收率（连续流反应

器）

Conversion vs. chlorine/SM mole ratio Yield vs. reaction temperature

conv

ersi

on Yiel

d

Batch Conversion

AFR ConversionBatch Yield

AFR Yield

0%10%20%30%40%50%60%70%80%90%

100%

10% 20% 30% 40% 50%

收率

反应物浓度


器）

收率（常规反应器

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

收率

反应时间


器）

Yield vs. reaction timeYield vs. SM concentration%

Yiel

d

Yiel

d

AFR YieldBatch YieldAFR Yield

Batch Yield



AFR for Continuous Production of Y2010A:Simplified process with improved yield and purity

Organic lubricant additives:Y2010A ( methylene-bis-dibutyldithiocarbamate)

Market: 3500 t/y, 2 step complicated synthesis

=> 1 step stable synthesis Increased yield from 85% to

92% Improved purity from 97% to

99% Reduced reaction time from

10 hours to 1 minute Filed 3 process Chinese

patents

1 Step

99%

92%

85%

97%

10 hours

2 Steps

Batch



Flow Chemistry Helped Deliver Green Continuous Process:Eliminated solvent use & extraction, distillation etc steps

HATP Batch AFR

Yield 67%-75% Quantitative Yield

Purity >97.0% >97.0%

B/A Molar Ratio 1.10 1.02

ProductionStability

The qualityvaries by batch

Stable

Solvent Yes No

Waste Water Yes No

Energy Use Distillation Min to control Temp

Process

ExtractionConcentration

DryingFractionalDistillation

No.Pump off volatile

30t/y CMO production in Laviana China (2012)

Courtesy of Laviana

Courtesy of Laviana



Changzhou University: China National Award fordevelopment of flow process of nitro-guanidine

Chinese Patent



Seamless Scaleup: From G1 to G4：

HNO3LiquidCatalyst

SM

Process development was doneon AFR™ G1 platform

Optimized mole ratio, reactiontemperature, flow rate,residence time, dosing method,and other parameters.

Project duration: 4 weeks!

ProductMix

Based on G1 data, Corning designedG4 reactor.

All parameters are the same exceptthe flow throughput increased by 25times and led to annual throughputof 2000 tons.

Absolutely seamless scale-up!

Nanjing Refinery Co., Ltd. China

Process Development in G1 Production Realized in G4



More G4 Production Commissions Happening Globally



Globally - Growing Interest in Corning AFR™ Technologyand Applications in Pharma, Fine & Specialty Chemicals



Concluding Remarks• AFR™ technology is an Inherently Safer Technology (IST) that drastically

reduces the consequences of an accident on the plant environment, however itdoes not prevent using the good & safe practices developed by the chemicalindustry.

• Successfully demonstrated seamless scale-ups providing customers increasedconfidence in adopting this technology

• We are proud of seeing our long-list of G4 production projects going on in Asiaand Europe

• AFR™ technology and Green Chemistry goes with hand in hand

Contacts: [email protected]://www.corning.com/reactors

…Thank you….



Corning Application Lab in Indiahelp customers adopt AFR technologies

AFR™ ReactorAuxiliary Operation

Demo

Fast Track Tests(FTT); Quick

Feasibility Tests(QFT)

Flow ChemistryProcess

Development

Documents

Innovation Drives Green Growth - Industrial Green · PDF fileInnovation Drives Green Growth: Advanced Flow Reactor Technology - Industrial Production Made Real Agenda ... Corning Incorporated