Katarzyna Szymańska, Klaudia Odrozek, Aurelia Zniszczoł, Wojciech Pudło, and Andrzej B. Jarzębski Chem. Eng. J., 2017, 315, pp. 18-24.
Time lapse video demonstrating a prototype vehicle capable of processing two cubic metres of coloured water within five minutes. The raft was carrying two rotating bed reactors that neutralized the basic surface water in a square pond by ion exchange.
Activated carbon is a common choice for removing impurities or capturing compounds from a product batch. However, the carbon may itself foul the product and be difficult to separate. The rotating bed reactor offers a clean way to deploy activated carbon that removes the need for time-consuming filtration and extends the lifetime of the solid phase.
Soudabeh Saeid, Pasi Tolvanen, Narendra Kumar, Kari Eränen, Janne Peltonen, Markus Peurla, Jyri-Pekka Mikkola, Andreas Franz, and Tapio Salmi Appl. Catal. B, 2018, 230, pp. 77-90.
The rotating bed reactor (RBR) is a combined tool for chemical transformations and liquid transfer operations, reducing or eliminating the need for external pumps. Filled with a catalyst or adsorbent, and rotated by a motor, the RBR brings the liquid to be processed in contact with the solid-phase at high flow rates. Due to the high flow rate generated, the RBR can not only treat the liquid in the reaction vessel, but also transfer it into the vessel for processing.
Automation of large-scale processes is often a requirement for economically viable chemical processes. The benefits of scale are best harvested at high throughputs and 24/7 operation. This leads to the demand for process automation, and the elimination of hands-on work.
Time lapse video showing how straightforward it is to use immobilized enzymes in a rotating bed reactor. A substrate giving a yellow coloured product was used to follow the reaction progress of an ester hydrolysis by an immobilized lipase. This substrate is commonly used to screen and characterize lipases.
Roger A. Sheldon and Pedro C. Pereira Chem. Soc. Rev., 2017, 46(10), pp. 2678-2691.
Enzyme screening is an important step in the development of a biocatalytic application. The behaviour of the biocatalyst is often hard to predict, meaning that different combinations of materials and reaction conditions need to be tested.
Tung Ngoc Pham, Ajaikumar Samikannu, Anne-Riikka Rautio, Koppany L. Juhasz, Zoltan Konya, Johan Wärnå, Krisztian Kordas, and Jyri-Pekka Mikkola Top. Catal., 2016, 59, pp. 1165-1177.
Hilde Larsson, Patrick Alexander Schjøtt Andersen, Emil Byström, Krist V. Gernaey, and Ulrich Krühne Ind. Eng. Chem. Res., 2017, 56, 14, pp. 3853-3865.
Heterogeneous catalysis can be an effective tool for chemical synthesis, particularly in the discovery and development of pharmaceutical ingredients. The handling of these solid catalysts is sometimes challenging as it leads to more unit operations in the factory scale, as well as introduces additional work-up in the laboratory.
Removing ions from liquids is common in industry and society. Ions are remediated in applications ranging from the production of pharmaceuticals to the treatment of communal waste streams. Likewise, the nuclear energy sector deals with the removal of ionic radioactive substances from water on a daily basis.
A fixed bed reactor (FBR), also known as a packed bed reactor or column, is a traditional technology for processes such as adsorption or heterogeneous catalysis. Achieving the required level of purification or conversion means running the liquid through the reactor at a sufficiently low flow rate, and the throughput of a fixed bed reactor is therefore often limited.
Mass transfer limited reactions can create problems for applications like the synthesis of chemical products or the manufacture of active pharmaceutical ingredients. Poor yields, high side-product formation or impractically long reactions are potential issues. Efficient reactor design can greatly improve the mass transfer and remove the limitation to a minimum.
Liquids with high viscosity create problems for heterogeneous applications in traditional reactors. Packed bed reactors (columns) suffer from huge back pressures, and stirred tank reactors (STR) exhibit reduced reaction rates due to poor mixing. Both issues lead to longer processing times and expensive operations.
Adsorption of methylene blue (3 g, 5 mg/L) onto Purolite® NRW1160 (4.2 L) placed in a SpinChem® S5 RBR operated at 147 rpm. The SpinChem® S5 RBR was placed within a 600 L IBC tank, using the ProRBR IBC add-on, where the tank was filled with water. The data was acquired using a UV-VIS spectrophotometer.
Decolorization, pesticide remediation, catalysis, and many other applications involve dealing with viscous liquid that needs to be modified in some way. The rotating bed reactor presents an efficient way to treat viscous liquids, without the challenges of conventional reactors.
A large scale decolourization experiment using the SpinChem® rotating bed reactor (RBR) S100, packed with 79 L of activated carbon. The vessel contained 7000 L of water with added methylene blue dye. In under 40 minutes, 95% of the initial concentration of methylene blue was removed from the water, which shows that the RBR S100 can achieve fast reaction times in large scale processes.
The rotating bed reactor (RBR) is a clean way to use activated carbon for purification, which eliminates the need for time-consuming filtration and extends the lifetime of the solid phase. It is available on scales ranging from milliliters to hundreds of cubic meters and offers faster decolorization, elimination of filtration, and extended adsorbent lifetime.
Valerie Eta and Jyri-Pekka Mikkola Carbohydr. Polym., 2016, 136, pp. 459-465.
The SpinChem® rotating bed reactor (RBR) S100, with a solid phase capacity of 100 L, was used to deionize 7000 L of tap water. The RBR S100 was operating at 160 rpm and filled with 36.5 L of mixed bed ion exchange resin. The results show that the RBR S100 can efficiently process large liquid volumes. As shown by the successful deionization, the performance of the RBR remains high even when it is partially filled, which proves the extreme robustness of the RBR technology.
The separation of a heterogeneous catalyst, an adsorbent, or an ion-exchange resin from a liquid product is a time-consuming unit operation that often makes the use of these materials impractical. The rotating bed reactor is a more efficient technology for deploying catalysts for manufacturing or adsorbents for purification.
Philipp Petermeier, Jan Philipp Bittner, Simon Müller, Emil Byström, and Selin Kara Green Chemistry, 2022, 24(18), pp. 6889-6899.
Cold, long nights mark the season in northern Sweden. The snow cover lies thick, and any shelter from the elements is welcome. At these times, we crave a warming beverage more than ever.
When working with an emulsion (and particularly with a heterogeneous catalyst) the mass transfer between the phases is critical. Insufficient mixing leads to lower interfacial area per volume, and in turn to poor mass transfer across the phases.
Fixed bed reactors (FBRs), also known as packed bed reactors (PBRs), are frequently used for purification, ion-exchange processes, or heterogeneous catalysis. Though relatively easy to construct, they are tedious to charge with solids in an effective way. A poorly packed FBR is subject to channelling, where passages are formed in the bed. These passages offer less resistance to the liquid, which will preferentially travel through those regions. In this work, the robustness with respect to channelling of a packed bed reactor was compared to a rotating bed reactor (RBR) using computational fluid dynamics (CFD).
Hendrik Mallin, Jan Muschiol, Emil Byström, and Uwe T. Bornscheuer ChemCatChem, 2013, 5, pp. 3529-3532.
Whole cell biocatalysis is powerful, but not straightforward. One way of utilizing whole cells is to encapsulate them in a matrix such as alginate to make them easier to separate from a reaction mixture. However, alginate beads are not mechanically stable enough to be packed into columns and are easily destroyed in stirred tank reactors (STR). This makes enzyme recycling ineffective, at the same time as mass transfer limitations may prevail.
Valerie Eta, Ikenna Anugwom, Pasi Virtanen, P. Mäki-Arvelaa, and Jyri-Pekka Mikkola Ind. Crops Prod., 2014, 55, pp. 109-115.
Finding the optimal chemistry and solid-phase material for immobilization of enzymes relies heavily on trial and error. The right resin will ensure satisfactory immobilization yield, as well as high activity and stability of the enzyme.
Adriana Freites Aguilera, Pasi Tolvanen, Shuyana Heredia, Marta González Muñoz, Tina Samson, Adrien Oger, Antoine Verove, Kari Eränen, Sebastien Leveneur, Jyri-Pekka Mikkola, and Tapio Salmi Ind. Eng. Chem. Res., 2018, 57(11), pp. 3876-3886.
Ran Duan, Bo S. Westerlind, Magnus Norgren, Ikenna Anugwom, Pasi Virtanen, and Jyri-Pekka Mikkola BioRes., 2016, 11(4), pp. 8570-8588.
As a tool for heterogeneous catalysis, or purification of liquids using materials like activated carbon, the rotating bed reactor provides high throughput capability frequently exceeding traditional technologies.
Large volumes of liquid waste will often accumulate at industrial sites. It may be very time-consuming and resource-intensive to adequately treat these waste streams for release, so the problem often compounds over time.
Ariana Causevic, Eimantas Gladkauskas, Kim Olofsson, Patrick Adlercreutz, and Carl Grey Biochem. Eng. J., 2022, 187, 108610.
Ikenna Anugwoma, Luis Rujana, Johan Wärnå, Mattias Hedenström, and Jyri-Pekka Mikkola Chem. Eng. J., 2016, 297, pp. 256-264.
Video showing how a SpinChem® rotating bed reactor (RBR) was charged with solid particles, followed by draining and replacing the reaction liquid without escape of solids. Lastly, the solid phase was removed without opening the RBR. This procedure illustrates a concept for automatic handling of solid phases in production scale equipment without opening the reaction vessel.
How can this process be scaled up? This is perhaps the most important question to consider when developing a chemical process. If it cannot be done on large scale, all the time and resources invested in laboratory work will be unrewarded. Pumping liquids through massive columns or separating solids from a large batch can be unsurmountable challenges that bring a halt to a new project before it has even left the starting blocks.
Anup Ashok and Santhosh Kumar Devarai 3 Biotech, 2019, 9(9), 349.
Carl-Johan Aurell, Staffan Karlsson, Fritiof Pontén, and Søren M. Andersen Org. Process Res. Dev., 2014, 18(9), pp. 1116-1119.
The SpinChem rotating bed reactor (RBR) can eliminate poor mass transfer in heterogeneous reactions during chemical syntheses and biotransformations, preserve catalyst activity, and facilitate recycling of solid phases. This brochure presents our technology and its applications.
Jochen Wachtmeister, Philip Mennicken, Andreas Hunold, and Dörte Rother ChemCatChem, 2016, 8, pp. 607-614.
Jens Johannsen, Francesca Meyer, Claudia Engelmann, Andreas Liese, Georg Fieg, Paul Bubenheim, and Thomas Waluga AIChE J., 2021, 67(4), e17158.
Roger A. Sheldon, Alessandra Basso, and Dean Brady Chem. Soc. Rev., 2021, 50(10), pp. 5850-5862.
Many heterogeneous processes are limited by mass transfer at typical laboratory or industrial conditions. When using a rotating bed reactor, the mass transfer is most easily controlled using the rotational speed.
Pesticide residue can ruin a batch of a botanical extract, creating large problems for producers. Curated adsorbents, specifically chosen for your situation, can be used to remediate the pesticides. With a rotating bed reactor, you are equipped to respond to contaminants showing up on your test results.
Oliver Fellechner and Irina Smirnova Can. J. Chem. Eng., 2021, 99, pp. 1035-1049.
Alexandra V. Chatzikonstantinou, Αrchontoula Giannakopoulou, Stamatia Spyrou, Yannis V. Simos, Vassiliki G. Kontogianni, Dimitrios Peschos, Petros Katapodis, Angeliki C. Polydera, and Haralambos Stamatis Environ. Sci. Pollut. Res., 2022, 29, pp. 29624-29637.
S. Lokesha, Y. S. Ravi Kumar, P. S. Sujan Ganapathy, Prashant Gaur, and H. M. Arjun 3 Biotech, 2021, 11, 410.
Pobitra Halder, Sazal Kundu, Savankumar Patel, Adi Setiawan, Rob Atkin, Rajarathinam Parthasarthy, Jorge Paz-Ferreiro, Aravind Surapaneni, and Kalpit Shah Renewable Sustainable Energy Rev., 2019, 105, pp. 268-292.
Ingeborg Heuschkel, Selina Hanisch, Daniel C. Volke, Erik Löfgren, Anna Hoschek, Pablo I. Nikel, Rohan Karande, and Katja Bühler Eng. Life Sci., 2021, 21(3-4), pp. 258-269.
M. Aßmann, A. Stöbener, C. Mügge, S. K. Gaßmeyer, L. Hilterhaus, R. Kourist, A. Liese, and S. Kara React. Chem. Eng., 2017, 2(4), pp. 531-540.
Jochen Wachtmeister and Dörte Rother Curr. Opin. Biotechnol., 2016, 42, pp. 169-177.
Biocatalysis is a useful method for the synthesis of small chiral molecules, offering new possibilities for the synthesis of active pharmaceutical ingredients and other compounds. The rotating bed reactor has been established as an efficient way to deploy enzymes in production as well as research and development.
Investigating reactions can easily grow from an idea into very time-consuming projects, but the upside of properly understanding the reaction is great. The choice of equipment has a very large impact on the efforts required. The rotating bed reactor is a tool that unlocks the full potential of your Mettler-Toledo EasyMax™ 102 Advanced synthesis workstation for this development.
The versatility of the ProRBR IBC add-on (picture below) was demonstrated by mounting it on a high-integrity container (HIC) (picture above) and running a sample reaction. The ProRBR IBC add-on can be placed on most reasonably stable supports. In this case, the RBR add-on was placed over the HIC opening by support of a common construction scaffold. A common ion-exchange reaction, de-ionization of 3000 L municipial water by 7 L of mixed-bed resin, was carried out to assess performance. The conductivity was halved after only about 30 min and after 2 h it reached the LOQ.
Roger A. Sheldon and John M. Woodley Chem. Rev., 2018, 118(2), pp. 801-838.
This case study presents a lipase-mediated stereoselective acetylation of a racemic amine in a rotating bed reactor.
Stirred vessels tend to damage soft heterogeneous catalysts, like enzymes immobilized in agarose or alginate beads, with activity loss and tedious workup as consequence. In a fixed bed reactor, these materials are easily compressed by the pressure gradient, leading to a loss of flow rate. Overcoming these challenges opens up the possibility to use biocatalysis as a tool for greener processes and more sustainable manufacturing.
When using of solid-phase catalysts or adsorbents in reactors, the physical degradation of the materials is a common problem. The traditional stirred tank reactor inflicts mechanical damage to the particles, which causes attrition, fines that are difficult to separate, and loss of the functionality of the solid-phase.
Contaminations in liquids can often be removed using an adsorbent, such as granular activated carbon (GAC). The best choice of adsorbent is unique for each contaminant, and the effectiveness depends on many parameters. Failing to investigate these can lead to unnecessarily high material costs and long processing times.
Screening immobilized enzymes to find the best match with the substrate and reaction conditions can be a time-consuming process. The introduction of the solids in a stirred tank reactor leads to damage to the immobilized biocatalysts and makes filtration necessary.
The SpinChem rotating bed reactor (RBR) has been proven to be a time and labor-efficient tool in the screening of biocatalysts. Here, we present the quick simultaneous screening of six different immobilized lipases for the esterification of lauric acid to propyl laurate using our pre-packed MagRBR lipase screening kit.
Research and development quickly takes new directions, and the requirements on a laboratory may vary with every new project. Limiting yourself to equipment with a narrow scope of conditions and applications may become expensive, since new equipment must be acquired for anything out of scope. With budgets quickly consumed by other projects, the need for new equipment may mean significant delays and a reduced capability to take on emerging opportunities.
The performance of a reactor for heterogeneous chemistry depends on the liquid flow it creates, and the mass-transfer rates it can achieve. Simulations help us investigate in high detail how a rotating bed reactor performs in any configuration.
The synthesis of products, such as active pharmaceutical ingredients (APIs), often involves multiple steps using heterogeneous catalysts or adsorbents. Thus, the simultaneous use of multiple solid phases either during synthesis or downstream processing is frequently highly advantageous.
Synthesis typically involves multiple reaction steps and the isolation of intermediate products. Any incomplete conversion at the end of each step will compound to an overall lower yield. To make things worse, the work-up of each intermediate can be very time-consuming. This has made one-pot cascade synthesis (the simultaneous execution of multiple steps in a single reactor) a desirable target for chemists. This approach aims to minimize intermediate work-up, reduce the risk of material loss, and enhance overall process efficiency.
Josefina Nyström, Ulla-Britt Östman, Torgny Mossing, Leif Hed, and Paul Geladi Food Anal. Methods, 2020, 13, pp. 933-941.
SpinChem Assembly Guide Video
SpinChem Instruction Video
Can you use a rotating bed reactor (RBR) in any type of vessel? - Absolutely! Would the performance be higher with baffles in the vessel? - Definitely!
Hydrogenation reactions using hydrogen gas are usually efficient and clean. Drawbacks are the safety issues of handling hydrogen gas, need for reactors made for pressurized reactions, and the necessity of vigorous stirring to make these solid-liquid-gaseous reactions work well.
A small rotating bed reactor (RBR) system deployed in an external loop to the customer’s regular reaction vessel. Even though RBR technique has been identified as offering advantages for a particular process, deploying it in an existing reaction vessel may prove difficult for practical reasons. This is were “plug-in” mode deployment of the RBR can offer a solution. The RBR and associated vessel is attached in an external loop by inlet and outlet connections to the regular vessel. The “plug-in” RBR system is typically small compared to the regular vessel. Alternatively, the RBR system can be deployed in a vessel → RBR → 2nd vessel mode. A proof-of-concept demonstration of an RBR in “plug-in” mode by a decolorization. The volume of the “plug-in” vessel is ca 0.7% of the regular vessel it is attached to.
Heterogeneous reactions involving viscous solutions put high demands on equipment and materials. Columns face high pressure drops and require powerful pumps and durable solid phase particles. Stirred tank reactors do not face the same problem, but the high liquid viscosity and low particle density will have a negative impact on reaction kinetics and require tedious filtration to separate the solids afterwards.
Research and development quickly takes new directions, and the requirements on a laboratory may vary with every new project. Limiting yourself to equipment with a narrow scope of conditions and applications may become expensive in the long run. The need for new equipment may inflict delays and affect your capability to take on emerging opportunities.
Subhash Pithani, Staffan Karlsson, Hans Emtenäs, and Christopher T. Öberg Org. Process Res. Dev., 2019, 23(9), pp. 1926-1931.
Shuke Wu and Zhi Li ChemCatChem, 2018, 10(10), pp. 2164-2178.
Plants accumulate heavy metals from the soil in which they grow, and consequently the metals are found in any extracts produced from them. If the soil contains high levels of heavy metals, the resulting concentrate may be unfit for human consumption, and need remediation.
Biocatalysis offers many benefits in the production of chemicals and active pharmaceutical ingredients. One major challenge has been the deployment of immobilized enzymes in an efficient way on large scale. The rotating bed reactor offers a convenient way to scale a biocatalytic process.
Catalyst recovery is an important step in downstream processing. Using an appropriate scavenger resin and a rotating bed reactor to deploy it, the recovery is straightforward and effective.
Sometimes you don’t want to pack the entire rotating bed reactor full with your solid-phase material. Fully loading might simply be wasteful, or you may want to experiment with your reaction conditions. But how does the amount of solids in the rotating bed reactor influence the reaction performance? Can you use only 10% of the full capacity?
Scavenging of soluble undesirable compounds and substances onto solid phase is used in a wide range of applications. In this example, a rotating bed reactor (RBR) is used to capture low concentrations of a phenol onto readily available Strong Anion Exchange (SAX) resin as a scavenger.
Teng Ma, Weixi Kong, Yunting Liu, Hao Zhao, Yaping Ouyang, Jing Gao, Liya Zhou, and Yanjun Jiang Appl. Biochem. Biotechnol., 2022, 194, pp. 4999–5016.
Adriana Freites Aguilera, Pontus Lindroos, Jani Rahkila, Mark Martinez Klimov, Pasi Tolvanen, and Tapio Salmi Chem. Eng. Process. Process Intensif., 2022, 174, 108882.
Krzysztof Polaczek, Eliza Kaulina, Ralfs Pomilovskis, Anda Fridrihsone, and Mikelis Kirpluks J. Polym. Environ., 2022, 30, pp. 4774–4786.
Markus Hobisch, Piera De Santis, Simona Serban, Alessandra Basso, Emil Byström, and Selin Kara Org. Process Res. Dev., 2022, 26(9), pp. 2761-2765.
Tobias Heinks, Nicolai Montua, Michelle Teune, Jan Liedtke, Matthias Höhne, Uwe T. Bornscheuer, and Gabriele Fischer von Mollard Catalysts, 2023, 13(2), 300.
Wilhelm Wikström, Adriana Freites Aguilera, Pasi Tolvanen, Robert Lassfolk, Ananias Medina, Kari Eränen, and Tapio Salmi Ind. Eng. Chem. Res., 2023, 62(23), pp. 9169-9187.
Christopher K. Prier, Karla Camacho Soto, Jacob H. Forstater, Nadine Kuhl, Jeffrey T. Kuethe, Wai Ling Cheung-Lee, Michael J. Di Maso, Claire M. Eberle, Shane T. Grosser, Hsing-I Ho, Erik Hoyt, Anne Maguire, Kevin M. Maloney, Amanda Makarewicz, Jonathan P. McMullen, Jeffrey C. Moore, Grant S. Murphy, Karthik Narsimhan, Weilan Pan, Nelo R. Rivera, Anumita Saha-Shah, David A. Thaisrivongs, Deeptak Verma, Adeya Wyatt, and Daniel Zewge ACS Catal., 2023, 13(12), pp. 7707-7714.
Daria Kowalczykiewicz, Katarzyna Szymańska, Danuta Gillner, and Andrzej B. Jarzębsk Microporous Mesoporous Mater., 2021, 312, 110789.
Adriana Freites Aguilera, Roosa Hämäläinen, Kari Eränen, Pasi Tolvanen, and Tapio Salmi J. Chem. Technol. Biotechnol., 2021, 96(7), pp. 1874-1881.
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Soudabeh Saeid, Matilda Kråkström, Pasi Tolvanen, Narendra Kumar, Kari Eränen, Jyri-Pekka Mikkola, Leif Kronberg, Patrik Eklund, Markus Peurla, Atte Aho, Andrey Shchukarev and Tapio Salmi Catalysts, 2020, 10(1), 90.
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Adriana Freites Aguilera, Jani Rahkila, Jarl Hemming, Maristiina Nurmi, Gaetan Torres, Théophile Razat, Pasi Tolvanen, Kari Eränen, Sébastien Leveneur, and Tapio Salmi Ind. Eng. Chem. Res., 2020, 59(22), pp. 10397-10406.
Robert Kourist and Javier González‐Sabín In: Biocatalysis for Practitioners: Techniques, Reactions and Applications
Roger A. Sheldon and Dean Brady ACS Sustainable Chem. Eng., 2021, 9(24), pp. 8032–8052.
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José Coloma, Yann Guiavarc'h, Peter-Leon Hagedoorn, and Ulf Hanefeld Catal. Sci. Technol., 2020, 10(11), pp. 3613-3621.
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Soudabeh Saeid, Matilda Kråkström, Pasi Tolvanen, Narendra Kumar, Kari Eränen, Markus Peurla, Jyri-Pekka Mikkola, Laurent Maël, Leif Kronberg, Patrik Eklund, and Tapio Salmi Catalysts, 2020, 10(7), 786.
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Kim Shortall, Katarzyna Szymańska, Cristina Carucci, Tewfik Soulimane, and Edmond Magner In: Biocatalyst Immobilization, Foundations and Applications, 2022
Environmentally benign and safe synthesis is enabled by highly active biocatalysts. To bolster economic and ecological aspects, catalyst reuse is essential and achieved by heterogenization of otherwise soluble enzymes onto solid supports. Here, this is demonstrated on novel renewable and non-polluting cellulose beads.
In the manufacture of liquid products, they may be coloured with appealing and brand-building colourants. During changes of batches, downtimes, or other regular day-to-day operations, coloured product residues are washed out of the process line. These are ideally recycled to minimize waste and maximize utility. For this, however, they need to undergo decolourization. Below we present a customer story in which the SpinChem RBR technoloy was deployed to decolourize viscous product residues.
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