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.

Catalyst coated StoliFlow tubes

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: Batch Reactor

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.

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