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20 batch reactors were replaced with a milli-reactor of just 7.5m in length.‘The batch paradigm is very good, because whatever you do, you can put into batch – but there can be inter-batch variation, for all sorts of reasons,’ explains Ollie Tames, director of technology at Intensichem, which designs and supplies continuous processing technology.Good heat transfer is achieved because of the high surface to volume ratio, which means reactions can often run at much lower temperatures than in batch.Processes can be scaled up by having multiple reactors in parallel.

By operating continuously, the same or greater volumes can be achieved, using far less energy. Moving to continuous processing means the size of the reactor can be reduced to such an extent that if it were to explode, the damage could be contained.It recently revealed that one of its reactors is being used successfully by China’s Nanjing refinery for an industrial nitration process, which has reduced the plant’s footprint.On a larger scale, AM Technology makes general purpose continuous reactors which employ active mixing – loose mixing elements in the reactor body are rotated or shaken, which makes them good at handling different materials such as gas and liquids.The same is true in India, where the generics industry has been rocked by a few high profile concerns about quality in recent years.For small to medium scale, chemical makers now have a lot of choice without having to choose bespoke systems. Ehrfeld’s plate-based modular system can be used to demonstrate that a process can run continuously in the lab.

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