Technology
Stoli Catalysts have developed novel methods for catalyst synthesis and binding catalysts to reactor surfaces. This patent-pending technology enables the design and manufacture of catalyst-coated tube reactors for efficient, continuous flow reactions with excellent control of the residence time, high product yield, and selectivity. Our reactors eliminate the need for cumbersome catalyst-product separation.
Key benefits
- Intensified reactions. Control over residence time allows the increase of specific reaction rates up to 8-fold compared to batch
- Excellent product quality. Rapid mass transfer and precise residence time control provide for reproducible impurity profile
- No need for catalyst separation. Catalysts are immobilised on the reactor walls allowing for reaction without difficult slurry separation
- Decreased labour costs. Elimination of repetitive non-productive steps in batch processes allows labour cost savings of 10-60%
- Improved process safety. Smaller reactor size of the flow reactor dramatically decreases risks associated with the continuous processes compared to batch
- Lower plant footprint. 24/7 operation in continuous flow and intensified production open a pathway for significant reduction (1-3 fold) in plant footprint
- Lower energy consumption. Smaller reactor sizes and elimination of heating/cooling cycles provides 2-10 fold reduction in energy consumption compared to batch processes
- Reduced waste. Use of solvents may be eliminated or reduced thanks to rapid heat transfer
- Lower capital costs. Smaller equipment size can cut capital costs by 40-65% compared to batch plant
Case Studies
Chemical Process Technologies: Continuous Stirred Tank Reactor
In our second series of chemical reactor fundamental videos, Dr Joe Socci will be giving an overview of CSTRs and how they differ to simpler batch reactors.
Chemical Process Technologies: Batch Reactor
We have recently created our first series of chemical reactor fundamental videos. In this overview, Dr Joe Socci, discusses the pros and cons of batch reactors by comparing five parameters – flexibility, scalability, reaction control, energy efficiency and catalyst lifetime.
Pyridine Chemisorption analysis service for characterisation of acid sites
We have recently published a case study on the pyridine chemisorption services we perform which determine the number of the corresponding acid sites in a material.
Raman Spectroscopy for online analysis: effect of gases, solids, laser power, aquisition time, signal/noise and more….
We investigated Raman spectroscopy for online analysis by monitoring hydrogenation reactions through relative peak intensities, subsequently, determine the concentration of components.
Cascading imine formation and hydrogenation
Stoli cascaded imine formation and hydrogenation; intensified process to maximise rate, and catalyst utilisation.
Process intensification in hydrogenation
Short residence time and high temperature – an impossible combination for batch – allowed increasing specific reaction rates 8-fold in flow with the same product quality.