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Dr. Yi Jiang, President & General Manager, Corning® Advanced-Flow™ Reactor Technology
As environmental and safety regulations become more stringent, the pharma and chemical industries are increasingly looking to continuous flow manufacturing as an inherently safer, more efficient, and less costly alternative to traditional batch processing.
The chemical plant blast in eastern China on March 21, 2019 has led to acceleration of inherently safer technology (IST) adoption such as advanced-flow reactors (AFR) based continuous manufacturing with integrated process automation and downstream continuous separation operations.
Corning has been promoting AFR continuous flow process applications globally and launched a portfolio of reactor products and auxiliary systems, covering lab development and industrial production. By integrating “seamless scale-up” design of “heart” channels, “sandwich type” modules and “hybrid type” reactor configurations with robust materials (glass, SiC and stainless-steel), we have achieved excellent mass and thermal transfers, strong resistances to thermal shocks, leading single unit 100 times flow scale up while keeping the same reaction performance.
This presentation will talk through two installed plant projects in China with nitration, diazotization, and hydrolysis involved, respectively. Both plants have been continuously running 24/7 for more than 25000, and 35000 hours with improved yield, reduced waste, as well as ROI less than 30 months. We will explain why Corning AFR has been able to ensure seamless scale up from the lab to 10000 my/yr/unit even with multiphases.