📋 Case Study

Pharmaceutical Continuous Flow Hydrogenation of API Intermediate

Exothermic runaway risk, inconsistent enantioselectivity, and metal leaching in batch mode

🏗️ Project Overview

Transition from batch Pd/C slurry hydrogenation to continuous flow for oncology drug intermediate

🎯 Challenge

Exothermic runaway risk, inconsistent enantioselectivity, and metal leaching in batch mode

🔧 Design Approach

Fixed-bed Pd/Al₂O₃ microreactor with back-pressure regulator, inline IR monitoring, and residence time distribution control

📐 Design Diagram

_La = 0.042 s⁻¹ BPR IR Design Metrics ΔT_ad = 89°C Residence Time Control • Exothermic runaway risk • Inconsistent enantioselectivity • Metal leaching Feed & Pump Reactor & IR BPR Challenges

AI-generated project design illustration

📐 Key Calculations

Mass Transfer Coefficient (k_La)

k_La = (6 × ε_g × u_s) / d_b

Result: 0.042 s⁻¹

Ensures H₂ availability at catalyst surface

Adiabatic Temp Rise (ΔT_ad)

ΔT_ad = −ΔH_rxn × C_A0 / (ρ × Cp)

Result: 89°C

Required active cooling design

📊 Results

99.2% ee maintained across 6-month run; 40% reduction in Pd usage; zero safety incidents

💡 Lessons Learned

• •Microreactor heat removal outperforms batch jacketing
• •Real-time analytics enable closed-loop quality control

✅ Key Takeaways

• 1Microreactor heat removal outperforms batch jacketing
• 2Real-time analytics enable closed-loop quality control