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1. Addis Ababa Science and Technology University School of Postgraduate Studies Department of Chemical Engineering Chemical Process and Product Design CURRENT STATE AND RESEARCH TRENDS ON STRUCTURED REACTVE DEVICES Prepared by: Sarah & Muluken Submitted to: Dr. Aman December 2025

2. Outline • Introduction • Catalytic Reactors • Micro-reacrors • Linking Structured Reactive Devices to Modern PI Trends • Current Industrial Applications • Industrial Adoption Challenges • Scaling & Throughput Challenge • Research Directions to Overcome Barriers • Ongoing Research Outlook

3. Introduction • Process Intensification (PI) refers to the development of chemical processes that are smaller, safer, more energy-efficient and more sustainable than conventional systems. • Structured reactive devices are reactors with engineered internal structures designed to intensify reaction and transport processes. • Reaction and transport enhancement occur simultaneously • Internal geometry is deliberately designed (channels, monoliths, packing) • Improves heat transfer, mass transfer and flow uniformity • Operates efficiently in a much smaller volume 1

4. CatalyticReactors • Catalytic reactor is a reactor where the chemical reaction occurs on a solid catalyst surface, accelerating reaction rate. • Working Principle • Reactants flow over or through a catalyst structure • Reaction occurs at active sites on the catalyst surface • Products leave while catalyst remains in place • Structured Reactors include: monolith reactors, micro-packed beds and structured internals with coated catalysts. • Structure matters BECAUSE it enhances reactant–catalyst contact, reduces diffusion resistance and improves heat removal. 2

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6. Micro-reactors • Microreactor is a reactor with micro-scale channels (micrometers to millimeters) that enable highly intensified reaction conditions. • Working Principle • Reactants flow through micro-scale channels (µm–mm range). • High surface-to-volume ratio enables: rapid heat removal, fast mass transfer and precise residence time control. • Reactions proceed under uniform, tightly controlled conditions, improving safety and selectivity. • Micro-scale Matters BECAUSE it prevents hot spots, enables fast and controlled reactions, and safe handling of hazardous chemistry. 4

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8. Linking Structured Reactive Devices to Modern PI Trends • Structured reactive devices align directly with modern PI goals of compactness, modularity and efficiency. Compactness • Structured catalysts and microchannels achieve high conversion in very small volumes. Modularity • Identical reactor units can be replicated and combined into flexible process systems. High efficiency • Enhanced heat and mass transfer • Improved selectivity and conversion per unit volume • Reduced energy consumption and waste generation 6

9. Current Industrial Applications Fine chemicals • For fast and highly exothermic reactions • Nitration, oxidation and hydrogenation reactions in continuous microreactors. Pharmaceuticals • Continuous synthesis of APIs with improved quality and reproducibility. • Lower inventory of hazardous intermediates Catalytic processing • Structured catalytic reactors used to reduce pressure drop, improve heat management drop and better catalyst utilization. • Used in: hydrogenation, oxidation and gas-phase reactions. Advanced materials synthesis • Microreactorsenable controlled nanoparticle formation and uniform product properties. 7

10. Industrial Adoption Challenges Technical challenges • Scale-up and throughput limitations • Catalyst deactivation and thermal stability • Fouling, sintering and mechanical durability of structured internals Safety challenges • Intensified operating conditions • Risk increases at system level when many units are combined Economic challenges • Higher capital cost due to precision manufacturing • Specialized operation and maintenance requirements 8

11. Scaling & Throughput Challenge • Scaling and throughput refer to the ability of a reactor system to achieve industrial production rates while maintaining performance, safety and control. • In microreactors, throughput is inherently limited by small channel dimensions, even though heat and mass transfer are excellent. • Increasing reactor size (classical scale-up) leads to loss of transport advantages, temperature gradients and safety risks. • As a result, production capacity is increased by operating many identical small units in parallel, rather than enlarging a single reactor. 9

12. Research Directions to Overcome Barriers Engineering solutions • Advanced flow distributors for uniform numbering-up • Additive manufacturing for complex reactor geometries Catalyst development • Thermally stable structured catalysts • Coated monoliths and tailored porosity supports Process control • Improved sensors and real-time monitoring • Model-based and digital control strategies 10

13. Ongoing Research Outlook • Development of robust structured catalysts resistant to thermal and chemical degradation. • Advanced reactor architectures using additive manufacturing. • Integration of digital twins, real-time sensors, and advanced control systems. • Hybrid systems combining intensified reactors with conventional units. • Expansion into sustainable applications such as hydrogen production and biomass conversion. 11

14. THANK YOU!