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Process Intensification

Definition of Process intensification

The aim of process intensification is to drastically increase the efficiency of processes (chemical and non-chemical). For instance the most basic idea for a chemical synthesis could be to shorten reaction times and to increase the yield.

Important approaches for process intensification include the reduction of process steps, acceleration of heat and mass transfer, use of micro process engineering, supply of non-classical energy forms (microwave, ultrasound,…), utilisation of extruder - rotor stator - membrane - cascade systems, application of plug flow and new methods in metrology, process control and operation and many more.


“Choosing the right process intensification tool for each specific challenge to maximize positive outcome”



Principles of Continuous Chemical Processing

Applications of continuous flow chemistry (continuous chemical processing), e.g. by the use of micro chemical engineering, is mainly leading to enhanced mass- and energy transport.

An enhanced heat transport phenomenon is attributed to higher surface to volume ratios compared to conventional reactors. Emerging heat from a reaction will be dissipated fast and efficient, allowing reactions to be carried out under isothermal conditions with exactly defined residence times.

Furthermore, mixing times in the range of few milliseconds are common for continuous processes through enhanced mass transport phenomena. Simultaneously the diffusion paths are short due to the smaller reactor dimensions as well leading to an increase in reaction rate.

Additionally accurate control of all relevant process parameters like temperature, pressure, residence time, flow rate, pH and many more is straightforward. Even in the case of highly exothermic or explosive reactions controlling your reaction is still possible without any danger.


A wide field of applications is opened up for Flow Chemistry, ranging from basic highly exothermic or cryogenic processes to gas phase reactions in explosive regimes and highly corrosive chemicals (conc. HF, conc. HCl, conc. H2SO4) as well as to the production of emulsions or particles with narrow size distributions up to complex chemical transformations involving a variety of byproducts, intricate kinetics in all possible physical states.


Micro reactors – Micro chemical engineering

Micro chemical engineering is gaining significant importance in the field of chemical engineering over the last decade. In micro chemical plants chemical reactions are carried out in three-dimensional structures with inner dimensions in the range of micrometers (µm). Serving for example the idea of higher process safety towards toxic or explosive substances, meanwhile significantly improving yield, selectivity and quality of the product, is causing Micro chemical engineering to be regarded as one of the key technologies in the chemical and pharmaceutical industry.

Microinnova already successfully supplied customers with processes at lab and production scale. One large scale process for a fine chemical manufacturer dealt with a several tons per hour productivity and another process for a big pharma company handled a 200 l/h ATEX (zone 1) and GMP-compliant flow process.


Where we are

Microinnova Engineering GmbH
Europapark 1
8412 Allerheiligen bei Wildon - AUSTRIA

T +43 3182 62626-0

M office@microinnova.com

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