Additively Manufactured Reactor for Enhanced Performance, Safety, and Sustainability in Chemical Processes
InnoSyn, founded in 2017 as a spin-out, has grown into an internationally recognized contract research organization (CRO). The company specializes in developing innovative chemical processes for clients across various industries, including agrochemicals, pharmaceutical intermediates and active ingredients, flavors and fragrances, and specialty chemicals. To meet its clients’ specific needs, InnoSyn employs cutting-edge technologies, such as custom-designed flow reactors manufactured through additive manufacturing (AM). For this, InnoSyn relies on toolcraft as a trusted partner.
The Starting Point:
Expanding the Functionality of Flow Reactors
To enable the safe development of chemical processes involving hazardous and fast reactions, InnoSyn employs continuous flow technology in reactors as a key solution. Using experimental, theoretical, and simulation-based approaches, the company has developed advanced in-house reactors. These reactors, featuring complex geometries and integrated sensors, allow for the safe handling of challenging chemical processes. Their innovative designs far surpass the capabilities of conventional manufacturing methods. With toolcraft as a partner, InnoSyn can realize these state-of-the-art reactors through additive manufacturing. toolcraft’s certification as a material manufacturer under the Pressure Equipment Directive 2014/68/EU enables the industrial use of its high-performance components.
The Challenge:
Complex Processes for Optimal Results
First, toolcraft had to successfully complete the certification process as a material manufacturer, which required a high level of professionalism in areas such as material properties, quality management systems, documentation, and communication with notified bodies. Additionally, the qualification and documentation requirements for the manufactured components needed to be defined.
The reactor design was thoroughly validated through simulations, which were necessary due to the component’s complex internal structure. The aim was to increase productivity compared to traditional batch processes while ensuring the reactor could be scaled to meet various production demands. Given the corrosive nature of the reagents, a specialized alloy with high strength, thermal fatigue resistance, and corrosion resistance at elevated temperatures was selected. The processing of Hastelloy C22 powder presented an additional challenge. Furthermore, the intricate internal structure of the component required the development of an intelligent depowdering strategy.
The Approach:
Combining Expertise
- Experiments and data analysis conducted by InnoSyn
- Reactor design, including sensor interfaces and cooling channels, developed using CAD by InnoSyn
- Design optimization with CAD and simulation software in collaboration with InnoSyn
- Fluid dynamics and strength simulations for the reactor design supported by Siemens
- Material selection
- Parameter development for L-PBF manufacturing
- Prototype production for testing on a smaller scale
- Creation of a material specification
- Certification under the European Pressure Equipment Directive
- Reactor manufacturing via additive processes
- Machining and post-processing of the reactor
- Quality assurance and preparation of required documentation
- Assembly of components into a final unit and approval as a pressure device by InnoSyn