Heterogeneous Catalysis

  • Modular and customizable setup
  • Direct scalability
  • Safety
  • Enhanced control and performance

Description

Whether working in batch or flow, most chemists and engineers encounter challenges
when performing difficult heterogenous catalysis processes. Zaiput Flow Technologies’
patented reactors make these reactions easier to handle by improving both safety and
performance.

Current Challenges in Heterogenous Catalysis

Our Reactor

  • Very efficient heat and mass transfer
  • High catalyst activity (powder)
  • Safe
  • Small footprint
  • Easily scalable
  • Moderate Pressure Drop

Reactions can be optimized at the lab scale and then directly scaled to production using
our technology.

Features

Important Features:

  • Bench top to plant scale
    Our devices are well-characterized and directly scalable from lab to pilot to production.
  • Modularity & Configuration Customization
    The reactor components (“blocks”) are modular layers which can be arranged in a custom order to build the perfect reactor configuration (“tower”) for any type of chemistry.
  • Minimal internal volume
    Our devices drastically reduce dead volume making the process safer while minimizing footprint and reagents consumption.
  • Continuous operation
    Our devices can boost productivity and can be easily used and integrated within either a batch process or a continuous one.

Other Advantages:

  • Cost effective
    Our devices come at a lower price than competing technologies. Our devices also
    reduce your operating costs thanks to minimal maintenance and highly efficient
    performance.
  • Excellent chemical compatibility
    Machined in materials with excellent chemical resistance, Zaiput separators work
    with a wide range of organic solvents, in acidic and basic solutions.
  • Green technology
    Our devices have excellent reaction performance and high yield and selectivity, boosting productivity.
    They are suitable for any catalytic reaction process, from bulk to high-value chemical industries.
  • Pressure rating
    The metal design allows Zaiput reactors to be used in-line with a pressurized
    process (up to 35 Bar).
  • Inherently safe
    No electricity is required, no headspace, and minimal internal volume.
  • Easy usage and maintenance
    Plug and play functionality at all scales.
  • Rapid Scaling
    Processes can be optimized at the lab scale and then directly scaled to production
    quickly thanks to the scaling geometry factor which maintains residence time and
    performance constant across scales.

How It Works

Zaiput Flow Technologies’ patented reactors allow to carry out continuous heterogenous
catalysis reactions (usually gas-liquid-solid catalyst) by optimizing the flow distribution
of the reagents through the device while maximizing catalyst utilization.

  • The two inlet streams (usually one liquid and one gas) enter the reactor at the bottom where they are mixed and distributed uniformly in the effective cross-section of the reactor.
  • By stacking different modules, such as mixing cartridges, catalytic cartridges, and heat exchanger modules, the reagents travel upward to a customized reactor configuration which can be optimized for a specific chemistry.
  • Reaction will happen in the catalytic layers, while mixing and heat exchange modules guarantee tight and efficient control over the reaction process.
  • The internal structure of the reactor components enhances mixing and mass transfer while maintaining plug flow characteristics. By flowing the reagents through the catalytic layer (rather than by) improves performance by lowering the characteristic length for mass transfer.
  • The reactor is also designed to maintain a constant temperature inside even when conditions are fluctuating.
  • The fluids then exit the reactor on the top from the outlet piece.

Catalyst Options

Packing your own catalyst

Zaiput also offers the possibility to use your own catalyst of choice inside our reactor. To do this, Zaiput has developed a “pack your own cartridge” concept where these packed cartridges can also be placed and used inside the reactor. Zaiput offers a packing setup that allows you to have a user-friendly, repeatable, and systematic way to pack those cartridges.

Contact us if you are interested in this option or would like to hear more about it. If you have any questions, contact us at support@zaiput.com

Applications

Zaiput reactor can be used to carry out many different classes of reactions such as:

  • Deprotection
  • Nitro reduction
  • Double bond reduction
  • Carbonyl reduction
  • Deoxygenation
  • Dehalogenation
  • Oxygenation
  • And more

Zaiput reactor allows to carry out these reactions in a small confined space with minimal head volume strongly improving on safety compared to batch approaches. Performance is also improved thanks to the substantial engineering design behind the reactor structure and its components.

Literature

Scientific articles featuring our separators:

Breen, Sean & Barua, Purnima & Fang, Yuan-Qing & Ford, David & Hasan, Ali & Joshi, Manish & Mason, Sara & Nagy, Kevin & Quadery, Sifat & Russell, Grace & Nikolakis, Vladimiros & Holcombe, John & Adamo, Andrea & Milani, Lorenzo. (2025). A Continuous Hydrogenation Reactor Based on a Powdered Catalyst Enmeshed in an Expanded Poly(tetrafluoroethylene) Matrix. Organic Process Research & Development. 10.1021/acs.oprd.4c00303.

Specifications

Tower Reactor – Laboratory Scale

Part Number TWR-10
Maximum Pressure 35 Bar (500 psi)
Wetted Parts 316-SS or Hastelloy C276, PTFE, FFKM
Liquid Flow Rate ~ 0.5-10 mL/min
Max Temperature 200°C
Gas Flow Rate ~ 20-500 sccm

*Scroll left to see more of the table

Tower Reactor – Pilot Scale

Zaiput membrane separator
Part Number TWR-100
Maximum Pressure 35 Bar (500 psi)
Wetted Parts 316-SS or Hastelloy C276, PTFE, FFKM
Liquid Flow Rate ~ 10-100 mL/min
Max Temperature 200°C
Gas Flow Rate ~ 300-5000 sccm

*Scroll left to see more of the table

Tower Reactor – Small Production Scale

Part Number TWR-1000
Maximum Pressure 35 Bar (500 psi)
Wetted Parts 316-SS or Hastelloy C276, PTFE, FFKM
Liquid Flow Rate ~ 100-1000 mL/min
Max Temperature 200°C
Gas Flow Rate ~ 3-50 slm

*Scroll left to see more of the table

Tower Reactor – Large Production Scale

Part Number TWR-10K
Maximum Pressure 35 Bar (500 psi)
Wetted Parts 316-SS or Hastelloy C276, PTFE, FFKM
Liquid Flow Rate ~ 1-10 L/min
Max Temperature 200°C
Gas Flow Rate ~ 30-500 slm

*Scroll left to see more of the table

Ordering Information

FAQ

FAQs about Zaiput reactors

What can Zaiput reactors be used for?

Zaiput reactors can be used to carry out continuous catalyzed heterogenous reactions, such as hydrogenation.

What is the pressure rating of the Zaiput reactor?

Zaiput reactors can go up to 35 bar. If more is needed, please contact us at support@zaiput.com for a potential customized option.

What is the temperature rating of the Zaiput reactor?

Zaiput reactors can go up to 200 ⁰C. If more is needed, please contact us at support@zaiput.com for a potential customized option.

What makes the Zaiput reactors unique among conventional reactors?

Zaiput reactor allows to carry out heterogenous catalyzed reactions continuously in a small,
confined space with minimal head volume strongly improving on safety compared to batch approaches. The modularity allows to reconfigure the reactor to address any chemistry (rather
than fit the chemistry for the reactor), while performance and control are also strongly improved
thanks to the substantial engineering design behind the reactor structure and its components.

Can Zaiput reactors handle acidic/basic solutions?

The standard material of construction is 316SS. However, to enhance chemical compatibility we also provide a version made with Hastelloy C276. Please contact Zaiput at support@zaiput.com for a potential customized option with a different material or added coating.

What throughput can the Zaiput reactors accommodate?

The lab scale Zaiput reactor can accommodate liquid flowrates up to 10 ml/min with a recommended max gas flowrate of 500 SCCM. The pilot scale reactor can accommodate liquid flowrates up to 100 ml/min with a recommended max gas flowrate of 5 SLM.

How often should I change the catalyst after use with chemicals?

The catalyst can be used continuously until activity (conversion) starts to drop below a certain threshold. At this point we recommend either add more fresh catalyst and/or replace the spent catalyst.