GB2608426A - Multi-disc catalytic reactor - Google Patents

Multi-disc catalytic reactor Download PDF

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Publication number
GB2608426A
GB2608426A GB2109514.6A GB202109514A GB2608426A GB 2608426 A GB2608426 A GB 2608426A GB 202109514 A GB202109514 A GB 202109514A GB 2608426 A GB2608426 A GB 2608426A
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Prior art keywords
disc
catalytic reactor
catalyst
immobilized
housing
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GB202109514D0 (en
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Shivaprasad Parimala
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Smdr Ltd
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Smdr Ltd
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Priority to GB2109514.6A priority Critical patent/GB2608426A/en
Publication of GB202109514D0 publication Critical patent/GB202109514D0/en
Publication of GB2608426A publication Critical patent/GB2608426A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
    • B01F25/70—Spray-mixers, e.g. for mixing intersecting sheets of material
    • B01F25/74—Spray-mixers, e.g. for mixing intersecting sheets of material with rotating parts, e.g. discs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F33/00—Other mixers; Mixing plants; Combinations of mixers
    • B01F33/80—Mixing plants; Combinations of mixers
    • B01F33/836—Mixing plants; Combinations of mixers combining mixing with other treatments
    • B01F33/8362—Mixing plants; Combinations of mixers combining mixing with other treatments with chemical reactions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0053—Details of the reactor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/18—Stationary reactors having moving elements inside
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J4/00—Feed or outlet devices; Feed or outlet control devices
    • B01J4/001—Feed or outlet devices as such, e.g. feeding tubes
    • B01J4/002—Nozzle-type elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J4/00—Feed or outlet devices; Feed or outlet control devices
    • B01J4/001—Feed or outlet devices as such, e.g. feeding tubes
    • B01J4/004—Sparger-type elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J4/00—Feed or outlet devices; Feed or outlet control devices
    • B01J4/001—Feed or outlet devices as such, e.g. feeding tubes
    • B01J4/007—Feed or outlet devices as such, e.g. feeding tubes provided with moving parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/008—Details of the reactor or of the particulate material; Processes to increase or to retard the rate of reaction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/04—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/04—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
    • B01J8/0446—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds the flow within the beds being predominantly vertical
    • B01J8/0461—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds the flow within the beds being predominantly vertical in two or more cylindrical annular shaped beds
    • B01J8/0469—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds the flow within the beds being predominantly vertical in two or more cylindrical annular shaped beds the beds being superimposed one above the other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/04—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
    • B01J8/0492—Feeding reactive fluids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/08—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with moving particles
    • B01J8/10—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with moving particles moved by stirrers or by rotary drums or rotary receptacles or endless belts
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M1/00—Apparatus for enzymology or microbiology
    • C12M1/12—Apparatus for enzymology or microbiology with sterilisation, filtration or dialysis means
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M3/00—Tissue, human, animal or plant cell, or virus culture apparatus
    • C12M3/06—Tissue, human, animal or plant cell, or virus culture apparatus with filtration, ultrafiltration, inverse osmosis or dialysis means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/00796—Details of the reactor or of the particulate material
    • B01J2208/00893—Feeding means for the reactants
    • B01J2208/00911—Sparger-type feeding elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/02—Processes carried out in the presence of solid particles; Reactors therefor with stationary particles
    • B01J2208/021—Processes carried out in the presence of solid particles; Reactors therefor with stationary particles comprising a plurality of beds with flow of reactants in parallel
    • B01J2208/022—Plate-type reactors filled with granular catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/02—Processes carried out in the presence of solid particles; Reactors therefor with stationary particles
    • B01J2208/023—Details
    • B01J2208/027—Beds
    • B01J2208/028—Beds rotating
    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
    • C12M21/00—Bioreactors or fermenters specially adapted for specific uses
    • C12M21/18—Apparatus specially designed for the use of free, immobilized or carrier-bound enzymes

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Bioinformatics & Cheminformatics (AREA)
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  • General Health & Medical Sciences (AREA)
  • Genetics & Genomics (AREA)
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Abstract

A multi-disc catalytic reactor comprising: a housing defining a cavity; at least one inlet in communication with the cavity and configured to communicate with one or more reagent feed streams; at least one outlet in communication with the cavity and configured to provide one or more product feed streams; a rotatable shaft located within and rotatable relative to the cavity of the housing; a drive means in communication with and operable to rotate the shaft; and a plurality of immobilized catalyst discs comprising a mesh support and a catalyst immobilized thereon are located within the reactor, wherein the discs are configured to be mounted on and rotatable with the shaft. The at least one inlet may comprise one or more nozzle rings mounted above the catalyst discs on the shaft or non-rotationally mounted. The nozzle ring may provide a plurality of spaced circumferential inlets which can be angled to point in the shaft rotation direction. The plurality of catalyst discs can be spaced e.g. equally, from each other along the shaft. The catalyst on at least one disc is preferably shear sensitive. A method for producing a pharmaceutical and a kit for use with the reactor are also described.

Description

MULTI-DISC CATALYTIC REACTOR
The present invention relates to a multi-disc catalytic reactor, and in particular to a multi-disc catalytic reactor suitable for shear sensitive catalysts. The present invention also relates to a method for using a multi-disc catalytic reactor.
BACKGROUND OF INVENTION
Catalysts are essential for multiple reaction steps when producing chemicals. The catalysts are either suspended in solution or immobilised on a surface. Immobilisation promotes re-use of expensive catalysts. However, the use of immobilised catalysts requires increased mixing, increased energy costs and catalyst disintegration whilst limits the application of conventional batch catalytic reactors.
Batch catalytic reactors have been used in multi-billion pound pharmaceutical and fine chemical industries for over 100 years due to ease of operation.
Batch reactors are easy to operate and a cost-effective solution for small scale operation. However, the use of batch reactors faces a significant challenge which it comes to multiphase reactions and reaction scale up. Unlike bulk chemicals, pharmaceutical products are produced at a scale of around 1000 -10000 tonnes per annum. Scaling-up production from the scale of the laboratory to mass production is associated with two main challenges: - Processing time for production at scale is longer compared to lab scale processes. This leads to catalyst degradation and deterioration of product quality over time which can lead to a reduction in productivity of the process; and - Lab scale productivity is optimised in equipment with lower volume capacity. However production at scale is carried out in large tanks or vessels which affects the homogeneity of the finished product and therefore leads to increased energy costs required to mix the reaction solution.
Modifications to the traditional batch reactor design over the years have improved productivity, however the conventional reactors are unsuitable for shear sensitive catalysts, such as enzymes, resulting in catalyst deactivation.
There is therefore a need for a cost-effective reactor which has the potential to support a range of catalytic reactions at varying production capacity without requiring additional modifications to the reactor design. There is also a need for a reactor which can be used at scale with shear sensitive catalysts.
SUMMARY OF INVENTION
According to a first aspect, the present invention provides a multi-disc catalytic reactor comprising: a housing defining a cavity; at least one inlet in communication with the cavity and configured to be in communication with one or more reagent feed streams, at least one outlet in communication with the cavity and configured to provide one or more product feed streams; a rotatable shaft located within and rotatable relative to the cavity of the housing; a drive means in communication with and operable to rotate the rotatable shaft; and a plurality of immobilized catalyst discs comprising a mesh support, in which the discs are configured to be mounted on and rotatable with the rotatable shaft.
The multi-disc catalytic reactor provides fast mixing, resulting in high mass transfer and reaction rates.
The multi-disc catalytic reactor of the present invention enables one-pot production of pharmaceuticals (and other chemicals) and therefore eliminates the need for intermediate product purification steps. As a result, the multi-disc catalytic reactor of the present invention reduces reactor downtime compared to the use of conventional batch reactors.
Furthermore, the multi-disc catalytic reactor of the present invention can be used by chemical and/or pharmaceutical companies to manufacture in-house with minimum upfront investment. As such, the multi-disc catalytic reactor of the present invention can reduce the reliance of chemical and/or pharmaceutical companies on imports and increases the reliable supply chain of key active pharmaceutical ingredients for life saving medicines.
The multi-disc catalytic reactor of the present invention can allow for scale up of active pharmaceutical ingredients in order to ensure domestic production to minimise the risk of failures in an overseas supply chain.
The multi-disc catalytic reactor of the present invention promotes clean growth within pharmaceutical and chemical industries by providing a reactor with improved chemical resource efficiency. The improved efficiency of the reactor ensures that the environmental impact of the reaction taking place within the reactor, for example the carbon emissions, is reduced. Furthermore, due to the improved efficiency of the multi-disc catalytic reactor, the operating volumes can be reduced whilst providing a high product yield compared to existing batch reactors. As a result, the use of the multi-disc catalytic reactor of the present invention offers safer working conditions compared to existing batch reactors.
The use of immobilized catalysts by the reactor of the present invention advantageously increases the ease of separation and catalyst reuse. As a result, the costs and environmental resources associated with the use of the reactor are significantly reduced.
The drive means is operable to rotate the rotatable shaft, about the longitudinal axis thereof, at any suitable speed dependent on the particular requirements for the reaction.
In one embodiment, the immobilized catalyst on one or more of the immobilized catalyst discs is a shear sensitive catalyst. The term "shear sensitive catalyst" is used herein to refer to catalysts, such as for example enzymes, which can be deactivated due to being exposed to centrifugal forces of the spinning disc.
The reactor preferably comprises at least one nozzle ring providing the at least one inlet. The nozzle ring(s) is preferably configured to be mounted on the rotatable shaft and located above a corresponding immobilized catalyst disc. The at least one nozzle ring is configured to be non-rotationally mounted above the corresponding immobilized catalyst disc(s). For example, the reactor may comprise a first stator plate mounted above one or more, preferably each, immobilized catalyst disc. The nozzle ring may be mounted on the first stator plate.
The nozzle ring may provide a plurality of inlets in any suitable arrangement on the ring. For example, the nozzle ring may provide a plurality of spaced apart circumferential inlets.
The inlet(s) of the nozzle ring are preferably configured to direct reagent feed stream in a predetermined direction relative to the corresponding underlying immobilized catalyst disc(s). The inlets may be directional inlets configured to direct the feed stream in a predetermined direction. Preferably, the at least one nozzle is configured to direct one or more reagent feed streams in the direction of rotation of the rotatable shaft, for example in the direction of rotation of the immobilized catalyst disc(s). In one embodiment, the or each inlet, for example the or each inlet of the nozzle ring, is angled to point in the direction of rotation of the rotatable shaft.
Preferably, the plurality of immobilized catalyst discs are spaced apart from each other along the rotatable shaft. The plurality of immobilized catalyst discs may for example be equally spaced apart from each other along the rotatable shaft.
The reactor may include multiple different catalysts within the reactor. Preferably, one catalyst is provided on each immobilized catalyst disc. In one embodiment, at least one of the immobilized catalyst disc comprises a catalyst which is different from the catalysts of the other immobilized catalyst discs. This arrangement enables multiphase reactions taking place in a one-pot reactor.
The reactor of the present invention allows for multiple catalysts, each preferably impregnated on a different disc, including non-compatible catalysts to be present within the same reactor.
The housing preferably comprises one or more run off plates located beneath a corresponding immobilized catalytic disc to receive product feed streams therefrom. The one or more run off plates are configured to direct received product feed stream towards the outlet.
The cavity of the housing of the multi-disc catalytic reactor may comprise a plurality of chambers, for example discrete chambers. The chambers are preferably spaced apart from each other along the length of the rotatable shaft. Each chamber preferably comprises: an inlet in communication with one or more reagent feed streams; an outlet configured to provide one or more product feed streams; and at least one immobilized catalyst disc mounted on a portion of the rotatable shaft extending within the chamber.
In one embodiment, the outlet of a first chamber is in communication with an inlet of at least one further chamber. In this arrangement, the product from a first chamber may be fed, as a reagent, into a further chamber for an additional reaction.
The multi-disc catalytic reactor may be a modular reactor. For example, the housing may be formed from a plurality of interconnectable housing portions. Each housing portion preferably comprises an upper end and an opposed lower end. Each end preferably defines an opening configured to receive the rotatable shaft therethrough. The opening provided by the upper end is preferably axially aligned with the opening provided by the lower end of the housing portion. Each housing portion preferably provides a chamber extending between the upper and lower ends thereof. The upper end of each housing portion is preferably configured to releasably engage the lower end of an adjacent housing portion. The modular arrangement of the multi-disc catalytic reactor ensures that the reactor can be scaled up or scaled down as needed depending on the particular requirements by adding or removing immobilized catalyst discs. The reactor of the present invention therefore allows for flexible manufacturing capacity.
In one embodiment, the housing is formed from a plurality of interconnectable housing portions. Each housing portion may comprise an upper end and an opposed lower end, each end defining an opening configured to receive the rotatable shaft therethrough. The lower end of one or more, preferably each, housing portion preferably provides a run off plate located beneath a corresponding immobilized catalytic disc to receive product feed streams therefrom. The one or more run off plates are preferably configured to direct received product feed stream towards the outlet.
In one embodiment, each immobilized catalyst disc is located above a second stator. The second stator preferably provides one or more peripheral cavities or recesses configured to receive product feed stream from the adjacent immobilized catalyst disc. The or each cavity or recess is preferably in communication with an outlet for collection of the product feed stream The product feed stream may for example be collected in one or more collecting tubes.
The mesh may for example be woollen cloth.
According to a second aspect of the present invention, there is a method for producing a pharmaceutical using a multi-disc catalytic reactor as herein described, the method comprising: obtaining a predetermined number of immobilized catalyst discs comprising a mesh support and a catalyst immobilized thereon, and mounting the discs on the rotatable shaft within the cavity of the housing; operating the drive means to rotate the rotatable shaft; supplying one or more reagent feed streams to the at least one inlet of the housing; collecting one or more product feed streams from the at least one outlet of the housing.
In one embodiment, the cavity comprises a plurality of chamber, further comprising supplying a product feed stream provided by an outlet of a first chamber of the housing to an inlet of a second chamber of the housing.
According to a further aspect of the present invention, there is provided a plurality of immobilized catalyst discs comprising a mesh support and a catalyst immobilized thereon for use with a multi-disc catalytic reactor as herein described.
According to a further aspect of the present invention there is provided a kit for use with a multi-disc catalytic reactor as herein described, the kit comprising one or more of: a plurality of immobilized catalyst discs comprising a mesh support and a catalyst immobilized thereon, in which the discs are configured to be mounted on and rotatable with the rotatable shaft of the multi-disc catalytic reactor; and/or a nozzle ring configured to be non-rotationally mounted on the rotatable shaft above a corresponding immobilized catalyst disc(s) of the multi-disc catalytic reactor, the nozzle ring comprising a plurality of spaced apart circumferential inlets.
Embodiments of the invention will now be described in greater detail with reference to the accompanying Figures.
BRIEF DESCRIPTION OF FIGURES
Figure 1 is a schematic illustration of a cross-sectional view of the multi-disc catalytic reactor according to one embodiment of the present invention.
DETAILED DESCRIPTION
With reference to the Figures, the multi-disc reactor 1 comprises a housing 2 defining a cavity 4. The reactor is a modular arrangement.
The housing 2 is formed from a plurality of interconnectable housing portions 6a, 6b. Each housing portion 6a,b comprises an upper end 8a,b and an opposed lower end 10a,b. Each end 8a,b, 10a,b defines an opening configured to receive a rotatable shaft 12 therethrough.
The opening provided by the upper end 8a,b is axially aligned with the opening provided by the lower end 10a,b of the housing portion 6a,b.
Each housing portion 6a,b provides a chamber 14a,b extending between the upper 8,b and lower 10a,b ends thereof.
The modular arrangement of the multi-disc catalytic reactor ensures that the reactor can be scaled up or scaled down as needed depending on the particular requirements by adding or removing immobilized catalyst discs. The reactor of the present invention therefore allows for flexible manufacturing capacity.
It is to be understood that although the illustrated embodiment shows the reactor 1 as having two housing portions 6a, b, the reactor 1 may have any suitable number of housing portions 6a, b depending on the particular requirements for the reactor.
The cavity 4 of the housing 2 of the multi-disc catalytic reactor 1 is provided as two separate chambers 14a,b. It can be seen from Figure 1 that the chambers 14a,b are spaced apart from each other along the length of the rotatable shaft 12.
Each chamber 14a,b comprises: an inlet 13a,b in communication with one or more reagent feed streams; an outlet (not shown) configured to provide one or more product feed streams; and an immobilized catalyst disc 16a, b mounted on a portion of a rotatable shaft 12 extending within the chamber 14a-d.
The lower end 10a of the first chamber 14a is shaped, for example angled, to provide run off plates to direct fluid flow towards an outlet (not shown). It is to be understood that the lower end of each chamber may be shaped to provide run off and direct fluid flow towards an outlet In the illustrated embodiment, each chamber 14a, b houses a single immobilized catalyst disc 16a,b. It is however to be understood that each chamber may house any suitable number of immobilized catalyst discs. The immobilized catalyst discs are spaced apart from each other along the length of the rotatable shaft 12.
Each immobilized catalyst disc 16a, b comprises a mesh support upon which a catalyst is immobilized. The catalyst may be any suitable catalyst, including for example shear sensitive catalysts.
For example, a four step procedure was used to immobilise copper triflate on wool. Mesh was cut into circular piece of diameter 12 cm, each weighing 12 g. The cloth was first treated with a solution containing hydrogen peroxide (30 %, 30 ml hi) and sodium silicate (2 g hi) in a pH 9 buffer (0.1 M sodium bicarbonate and sodium carbonate) for 70 min at 55 a1. The cloth was washed with deionised water thrice (5 minutes for every cycle) and air dried. The bleached cloth was then soaked for 2 hours at room temperature in a 2 % (w/v) solution of polyethyleneimine (PEI) (adjusted to pH 8 using hydrochloric acid) and washed with deionised water. Post surface modification with PEI, wool was soaked in a copper triflate solution in methanol (1 miMi) for 74 hours followed by immersing the cloth in a 0.5% (w/v)glutaraidehyde solution in pH 6 buffer (DIM sodium hydrogen phosphate and sodium dihydrogen phosphate) for 10 minutes for crosslinking and rinsed with &ionised water.
The catalyst immobilized on a first disc 16a may be different to the catalyst immobilized on one or more of the other discs 16b within the reactor 1. The discs 16a, b are mounted on and rotatable with the rotatable shaft 12. The reactor 1 of the present invention allows for multiple catalysts, each preferably impregnated on a different disc 16a, b, including non-compatible catalysts to be present within the same reactor 1.
Each inlet 13a,b is in communication with a nozzle ring 15a, b. Each nozzle ring 15a,b is configured to be mounted on the rotatable shaft 12 and located above a corresponding immobilized catalyst disc 16a,b. The nozzle ring 15a,b is non-rotationally mounted above the corresponding immobilized catalyst disc(s) 16a,b on a first stator plate 17. The nozzle ring 15a,b provides a plurality of spaced apart circumferential, directional nozzle inlets (not shown). The nozzle inlets are directional so as to direct the feed stream in the direction of rotation of the shaft 12 and disc 16a,b. This ensures that the reagent feed stream is evenly distributed from the nozzle inlets across the central portion of the disc 16a,b from the nozzle ring 15a,b, thereby creating an even flow across the surface of the disc 16a,b on which the catalyst is immobilized.
A second stator plate 19 is provided underneath the corresponding disc 16a,b. The second stator plate 19 provides a number of peripheral cavities or recesses in communication with an outlet (not shown).
The reactor 1 may include any suitable number of housing portions 6a,b and any suitable number of immobilized catalyst discs 16a,b depending on the particular requirements. The modular arrangement of the multi-disc catalytic reactor 1 of the present invention ensures that the reactor can be scaled up or scaled down as needed depending on the particular requirements by adding or removing immobilized catalyst discs. The reactor of the present invention therefore allows for flexible manufacturing capacity.
It is to be understood that the outlet of a first chamber 14a,b may be in communication with an inlet of at least one further chamber 14a,b. In this arrangement, the product from a first chamber may be fed, as a reagent, into a further chamber for an additional reaction. This arrangement enables a multiphase reaction to occur within a single reactor system.
The reactor 1 further comprises a drive means 18 in communication with and operable to rotate the rotatable shaft, about the longitudinal axis thereof, relative to the housing 2. The drive means is operable to rotate the rotatable shaft, about the longitudinal axis thereof, at any suitable speed dependent on the particular requirements for the reaction.
In use, the drive means 18 rotates the shaft 12 about the longitudinal axis thereof. Rotation of the shaft 12 drives rotations of the discs 16a,b mounted thereon. Reagent feed stream is then provided from the inlets of each nozzle ring 15a,b onto the surface of each underlying rotating disc 16a,b.
As the liquid flows across the surface of the disc 16a,b, the reagent reacts with the immobilized catalyst located thereon. The product feed stream is then directed towards and collected within the cavities or recesses of the second stator plate. The air flow created by the disc 16a,b forces the product feed stream through outlet for collection in collection tubes at outlet 20.
The multi-disc catalytic reactor of the present invention provides fast mixing, resulting in high mass transfer and reaction rates.
The multi-disc catalytic reactor of the present invention enables one-pot production of pharmaceuticals (and other chemicals) and therefore eliminates the need for intermediate product purification steps. As a result, the multi-disc catalytic reactor of the present invention reduces reactor downtime compared to the use of conventional batch reactors.
The use of immobilized catalysts by the reactor of the present invention advantageously increases the ease of separation and catalyst reuse. As a result, the costs and environmental resources associated with the use of the reactor are significantly reduced.
The reactor of the present invention can advantageously be used to scale up reactions using shear sensitive catalysts.

Claims (18)

  1. CLAIMS1. A multi-disc catalytic reactor comprising: a housing defining a cavity; at least one inlet in communication with the cavity and configured to be in communication with one or more reagent feed streams, at least one outlet in communication with the cavity and configured to provide one or more product feed streams; a rotatable shaft located within and rotatable relative to the cavity of the housing; a drive means in communication with and operable to rotate the rotatable shaft; and a plurality of immobilized catalyst discs comprising a mesh support and a catalyst immobilized thereon, in which the discs are configured to be mounted on and rotatable with the rotatable shaft.
  2. 2. A multi-disc catalytic reactor as claimed in claim 1, in which the reactor comprises at least one nozzle ring providing the at least one inlet, in which the nozzle ring(s) is configured to be mounted on the rotatable shaft and located above a corresponding immobilized catalyst disc.
  3. 3. A multi-disc catalytic reactor as claimed in either of claims 1 and 2, in which the at least one nozzle ring is configured to be non-rotationally mounted above the corresponding immobilized catalyst disc(s).
  4. 4. A multi-disc catalytic reactor as claimed in either of claims 2 and 3, in which the nozzle ring provides a plurality of spaced apart circumferential inlets.
  5. 5. A multi-disc catalytic reactor as claimed in any one of claims 2 and 3, in which the or each inlet is angled to point in the direction of rotation of the rotatable shaft.
  6. 6. A multi-disc catalytic reactor as claimed in any preceding claim, in which the plurality of immobilized catalyst discs are spaced apart from each other along the rotatable shaft.
  7. 7. A multi-disc catalytic reactor as claimed in claim 6, in which the plurality of immobilized catalyst discs are equally spaced apart from each other along the rotatable shaft.
  8. 8. A multi-disc catalytic reactor as claimed in any preceding claim, in which the immobilized catalyst on one or more of the immobilized catalyst discs is a shear sensitive catalyst.
  9. 9. A multi-disc catalytic reactor as claimed in any preceding claim, in which at least one of the immobilized catalyst disc comprises a catalyst which is different from the catalysts of the other immobilized catalyst discs.
  10. 10. A multi-disc catalytic reactor as claimed in any preceding claim, in which the housing comprises one or more run off plates located beneath a corresponding immobilized catalytic disc to receive product feed streams therefrom, in which the one or more run off plates are configured to direct received product feed stream towards the outlet.
  11. 11. A multi-disc catalytic reactor as claimed in any preceding claim, in which the cavity comprises a plurality of chambers, in which the chambers are spaced apart from each other along the length of the rotatable shaft, in which each chamber comprises: an inlet in communication with one or more reagent feed streams; an outlet configured to provide one or more product feed streams; and at least one immobilized catalyst disc mounted on a portion of the rotatable shaft extending within the chamber.
  12. 12. A multi-disc catalytic reactor as claimed in claim 10, in which an outlet of a first chamber is in communication with an inlet of at least one further chamber.
  13. 13. A multi-disc catalytic reactor a claimed in any preceding claim, in which the housing is formed from a plurality of interconnectable housing portions, each housing portion comprising an upper end and an opposed lower end, each end defining an opening configured to receive the rotatable shaft therethrough, and in which each housing portion provides a chamber extending between the upper and lower ends thereof, and in which the upper end of each housing portion is configured to releasably engage the lower end of an adjacent housing portion.
  14. 14. A multi-disc catalytic reactor as claimed in any one of claims 11 to 13, in which the housing is formed from a plurality of interconnectable housing portions, each housing portion comprising an upper end and an opposed lower end, each end defining an opening configured to receive the rotatable shaft therethrough, and in which the lower end provides a run off plate located beneath a corresponding immobilized catalytic disc to receive product feed streams therefrom, in which the one or more run off plates are configured to direct received product feed stream towards the outlet.
  15. 15. A method for producing a pharmaceutical using a multi-disc catalytic reactor as claimed in any one of claims 1 to 14, the method comprising: obtaining a predetermined number of immobilized catalyst discs comprising a mesh support and a catalyst immobilized thereon, and mounting the discs on the rotatable shaft within the cavity of the housing; operating the drive means to rotate the rotatable shaft; supplying one or more reagent feed streams to the at least one inlet of the housing; collecting one or more product feed streams from the at least one outlet of the housing.
  16. 16. A method as claimed in claim 15, in which the cavity comprises a plurality of chamber, further comprising supplying a product feed stream provided by an outlet of a first chamber of the housing to an inlet of a second chamber of the housing.
  17. 17. A plurality of immobilized catalyst discs comprising a mesh support and a catalyst immobilized thereon for use with a multi-disc catalytic reactor as claimed in any one of claims 1 to 14.
  18. 18. A kit for use with a multi-disc catalytic reactor as claimed in any one of claims 1 to 14, the kit comprising one or more of: a plurality of immobilized catalyst discs comprising a mesh support and a catalyst immobilized thereon, in which the discs are configured to be mounted on and rotatable with the rotatable shaft of the multi-disc catalytic reactor; and/or a nozzle ring configured to be non-rotationally mounted on the rotatable shaft above a corresponding immobilized catalyst disc(s) of the multi-disc catalytic reactor, the nozzle ring comprising a plurality of spaced apart circumferential inlets.
GB2109514.6A 2021-07-01 2021-07-01 Multi-disc catalytic reactor Pending GB2608426A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB2109514.6A GB2608426A (en) 2021-07-01 2021-07-01 Multi-disc catalytic reactor

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GB2608426A true GB2608426A (en) 2023-01-04

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1464389A1 (en) * 1999-02-17 2004-10-06 Protensive Limited Rotating surface of revolution reactor with rotary fan or impeller
US20070248510A1 (en) * 2006-04-25 2007-10-25 Dean Anne M Dual gas-liquid spargers for catalytic processing units
WO2017158611A1 (en) * 2016-03-14 2017-09-21 Patel Ravindrakumar Dhirubhai A bioreactor system and method thereof
WO2017222376A1 (en) * 2016-06-23 2017-12-28 Flowid Holding B.V. Spinning disc reactor

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1464389A1 (en) * 1999-02-17 2004-10-06 Protensive Limited Rotating surface of revolution reactor with rotary fan or impeller
US20070248510A1 (en) * 2006-04-25 2007-10-25 Dean Anne M Dual gas-liquid spargers for catalytic processing units
WO2017158611A1 (en) * 2016-03-14 2017-09-21 Patel Ravindrakumar Dhirubhai A bioreactor system and method thereof
WO2017222376A1 (en) * 2016-06-23 2017-12-28 Flowid Holding B.V. Spinning disc reactor

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