process
development

At Microinnova, process development is at the core of what we do. With chemistry as a key competence, we specialize in the development of efficient processes, especially difficult ones. Challenging processes do not have to equal challenging processing. Our one-stop-shop approach facilitates the execution of otherwise arduous operations by employing our MIC Fish methodology. Our chemists have a broad portfolio of experience working with 85+ different chemistries/chemical reactions, leaving not much to be desired in terms of possible routes to be taken to achieve the goals set by our clients. For a look at our laboratory infrastructure and the extensive list of specific chemistries and reactions we work with:

read more

One-Stop-Shop
for process intensification and continuous manufacturing

Our extensive experience, gained from over 250 projects across various industries, allows us to develop and optimize chemical processes and enhance efficiency, safety, and sustainability. We handle a wide range of chemistries, from specific reactions to complex work-up steps and formulation processes. Our boutique-style service ensures that each project is tailored to your needs, supported by the seamless collaboration of our chemists and engineers. Through a proven methodology, we intensify processes using flow chemistry, ensuring you achieve maximum efficiency and flexibility. We follow a structured approach to process development, ensuring that each step is meticulously planned and executed. Here’s a closer look at how we turn your ideas into efficient, continuous processes:

I Process Research
In this phase, we identify the best way to produce your chemical product. We start by finding the most efficient production route (route scouting) and then optimize it to use fewer steps and solvents. Our goal is to simplify the process and manage potential by-products effectively.

We define the key factors that influence the process using our MIC Fish methodology. We create a block flow diagram that outlines the steps for building the plant, including risk assessments and initial cost estimates. This helps us understand both chemical and engineering requirements.

Here, we develop and test the continuous process to ensure it works efficiently. We select the best technologies based on the key parameters identified. This step ensures the chemical process is optimized and ready for verification on scalable equipment in the next phase.

We verify the process using scalable equipment that simulates real production conditions. This ensures the process can be scaled up successfully. If needed, we conduct pilot trials to test specific technologies. This step generates important data to finalize the design for full-scale production.

read more

In this phase, we design the main components of the plant based on the User Requirement Specification (URS). We incorporate all process knowledge and offer advanced features like Process Analytical Technology (PAT) and model predictive control (MPC) to ensure efficient and reliable plant operation.

We complete the detailed design, assemble the plant, and conduct tests to ensure everything works perfectly. This includes the Factory Acceptance Test (FAT) and the Site Acceptance Test (SAT). On request, we handle installation, operational, and performance qualifications (IQ, OQ, PQ), automated by a flexible automation system based on MTP, and provide a Digital Twin.

Chemical Processes & Reactions
Our experience in 85+ Chemistries

Chemistry is a core competence of Microinnova. Over the years we have acquired from many different industrial applications in different branches.

Compiled below is an outline of the types of chemistry we have come across, representing both specifically named reactions and different reaction types.

Apart from chemical reactions themselves, we also specialize in workup steps as well as liquid and semi-solid formulations. If you have a question or would like to know how we can support your chemical production, please get in touch.

I Processes

Continuous Reactions and Flow Chemistry

Microinnova’s philosophy is to execute each reaction based on its specific requirements and critical process parameters. These parameters can vary significantly and may include controlling exothermic reactions, ensuring precise phase ratios and stoichiometry, maintaining uniform process conditions, and more. By utilizing advanced technologies, chemical reactions can be optimized to minimize workup efforts and enhance overall efficiency.

With more than 20 years of experience in flow process design, Microinnova has successfully executed over 250 projects in flow chemistry, emphasizing safety and product quality in exothermic reactions covering a wide range of organic chemistries. Various polymerization reaction projects, including free-radical and ionic polymerizations, as well as polyester and oligomer synthesis have been performed. Addressing safety concerns, Microinnova has expertise in handling materials with viscosities up to 100,000 mPas. Our polymer processes benefit from a specific cooling surface of up to 200 m²/m³, featuring a high k-value and narrow residence time distribution. Projects involving polymers encompass end-capping, functional group exchange, and cross-linking. Considering our expertise in more than 85 chemistries, we are your partner of choice in your quest to improve your processes.

Microinnova’s proficiency extends to halogenation reactions, showcasing significant experience in halogenating aromatic systems with elemental halogens (fluorine, chlorine, bromine, iodine) and hydrohalogenation with hydro-halides. Our core competence lies in flow process design and scale-up of challenging processes.

Synthetic fuels are a key part of future energy concepts. Microinnova has worked on several projects toward CO2 capture, methanol synthesis, Fischer-Tropsch synthesis, and other gas catalytic reactions. Within the BIOGO project, we have built modular lab plant systems. Flow chemistry offers improved safety, mass and heat transfer, as well as specialized condition handling. It responds to process needs and allows for the exploration of new conditions. Additionally, telescoping reactions in a continuous flow setup, streamlines processes and boosts process efficiency. Get in touch with our team to boost your processes to a new level.

  • Michael Addition
  • Robinson annulation reaction
  • Fischer Tropsch
  • Synthesis
  • Wittig Reaction
  • Wolff Kishner Reaction
  • Schotten Baumann Reaction
  • Favorskii Rearrangement
  • Mukaiyama Aldol Addition
  • Williamson ether synthesis
  • Suzuki-Miayaura Coupling
  • Reactions with BuLi
  • Reactions with HexLi
  • Reactions with Silica
  • Grignard Reagent Formation
  • Reaction with Grignard reagents
  • Reduction with Grignard reagents
  • Reduction reactions with Lithium-Aluminium-hydride
  • Various reactions with organo-metallic compounds
  • Hydrogenation of nitro-compounds
  • Hydrogenation of polymers
  • Hydrogenation of API intermediates
  • Oxidation reactions
  • Epoxidation of aromatics
  • Epoxidation of alkenes
  • Reactions with liquid ammonia
  • Liquified gases
  • Fischer-Tropsch
  • Methanol production using syngas
  • CO2 capture
  • Ionic and free radical polymerization
  • Monomer and oligomer synthesis
  • Synthesis of radical starters
  • Crosslinking, end-capping, modification, and functional groups 
  • Fluorination with Fluorine gas
  • Reactions with HF complexes
  • Hydro fluorination
  • Chlorination of alcohols
  • Selective chlorination of sidechains
  • Fluorination with SF4
  • Chlorination of aromatic compounds
  • Generation of bromine
  • Bromination reactions
  • Aromatic iodination
  • Synthesis of peroxy compounds
  • Ethoxylations
  • Propoxylations
  • Ether formation
  • Esterification
  • Transesterification
  • Sulfonation of heterocyclic compounds
  • Sulfonation of aromatic compounds
  • Nitration of aromatics
  • Acetylation
  • Acylation
  • Dehydration
  • Amidation
  • Hydrosilylation
  • Amination
  • Acetoxylation
  • Alkylation
  • Oxirane ring-opening with different molecules
  • Radical α-alkylation of ketones with alcohol
  • Synthesis of phenolic-novolac-type resin
  • TEMPO-catalyzed oxidation
  • Ionic liquid synthesis
  • Enzymatic oxidations
  • Enzymatic transesterifications
  • Enzymatic hydrolysis

Streamlining Chemical Processing with Tailored Continuous Flow Technologies

Continuous Workup and Downstream Processing

Microinnova’s core philosophy is to optimize chemical processes by reducing workup efforts and improving reaction efficiency. Essential downstream processes can be executed through continuous processing, tailored to the specific needs of each application. Typical unit operations include extraction, distillation, crystallization, liquid-solid separation, and drying.

Continuous Extraction

Various technologies are available for continuous extraction processes. Conventional methods include mixer-settler systems and extraction columns. Other common flow technologies include membrane separators and centrifugal extractors, which provide efficient phase separation and enhanced mass transfer.

Continuous Distillation

Continuous distillation has been widely used for many years. Since it is typically carried out in distillation columns, integrating it into skid-based modular plant systems requires customization based on project-specific needs.

Continuous Crystallization

Different technologies are applied in continuous crystallization, such as continuously stirred vessels and oscillated-buffer reactors. Depending on the process, it may be beneficial to separate the nucleation phase from the particle growth phase—especially when achieving a narrow particle size distribution is a key objective.

Continuous Formulation of Liquids and Pastes

Continuous formulation of liquids and pastes enables the development of more complex formulations. This can be achieved by generating pre-formulations or using different technologies and conditions to create specific substructures tailored to the desired properties.

read more
Laboratory

Chemical Process Development Capabilities
85+ Chemistries with Microinnova

With experience in over 85 different types of chemistries, Microinnova has supported a wide variety of chemical reactions and processes using flow chemistry technology.
Processing in flow typically enables much better process understanding and helps to increase the process capability. Typical advantages over traditional batch technology are a shift in mass and/or heat transfer, a reduction in the number of unit operations, or an increase in the safety level of the process. The philosophy of providing the best possible technology for a process or a chemical transformation leads to the realization of highly efficient processes.

I Special materials used in flow reactions
  • Silicon Carbide
  • Tantalum
  • Glass
  • Hastelloy
  • Various grades of steel
  • Pyrophoric or self-igniting substances
  • High viscosities up to 200,000 mPas
  • Hot and concentrated acids (e.g. HCl, Oleum)
  • Water H2O-sensitive processes
  • Generation and handling of solids (Precipitation, Crystallization…)
  • Up to 400 °C liquid processes
  • Down to – 60 °C for cryogenic processes
  • Up to 100 bar pressure
  • Nitrations
  • Ethoxylations
  • Propoxilations
  • Fluorinations
  • Hydrous & anhydrous hydro fluoride (HF), fluoride gas (F2)
  • Hydrous & anhydrous hydrochloric acid (HCl), chlorine gas (Cl2)
  • Ethylene oxide (EO)
  • Carbon monoxide (CO)
  • Flow calorimetry
  • Nuclear magnetic resonance (NMR) desktop flow
  • High-performance liquid chromatography (HPLC) systems, DAD
  • Gas chromatography (GC)
  • Particle size distribution (PSD) laser diffraction
  • Fourier transform infrared spectroscopy (FTIR)
  • Ultraviolet-visible spectroscopy (UV-VIS)
  • Viscosity – Brookfield, Hoeppler
  • Titration
  • pH in flow
  • Conductivity

Lab Facilities at Microinnova

Advancing chemical manufacturing through innovation.

LAB INFRASTRUCTURE
< 30 kg/h

  • 4 Process labs ​
  • 2 Analytic labs​
  • 1 Workshop​
  • 1 Pilot container​
  • 7 Walkable fume hoods​
  • 3 Standard fume hoods​
  • 2 Small fume hoods

TECHNOLOGIES 15+

  • AFR Corning glass
  • AFR Corning silica carbide
  • Div. static mixers Fluitec
  • Reaction/extraction column
  • Catalytic foam reactor
  • Extruder
  • Screw conveyors
  • Conti Rotor-Stator system
  • Gas-Catalytic reactor systems
  • Microreactors e.g., IMM
  • Autoclave
  • Tantal reactor
  • and others 

ANALYTICS

  • Flow Calorimeter​
  • NMR 60 MHz (desktop flow)​
  • 3 HPLC systems​
  • GC-FID, PSD​
  • FTIR Flow, UV-VIS ​Flow
  • Viscosity, titration, pH​
  • Conductivity​