When companies try to scale up chemical production from lab tests to large-scale manufacturing, they often face problems. Fluid flow and heat transfer behave differently in larger scale equipment than in small laboratory setups. This can lead to lower yields, poor quality, and inefficient processes. The usual approach to solve this is to make the equipment bigger (scale up), but this can be complex, costly, and often involves trial and error.
ReactoMod™ offers a new approach: instead of scaling up equipment, we scale out. This means using many smaller, identical units in parallel, that keep catalyst and bulk reactants in very close contact without the need for agitation. By doing this, we can keep the same reaction conditions (like temperature, pressure, and catalyst type) across the whole system, making the transition from research to full-scale production more predictable, and leading to higher quality and orders of magnitude increases in yield, with much smaller quantities of expensive catalyst.
The heart of the technology is achieving a stable, efficient reaction in the laminar flow regime. This means that the fluid moves smoothly and evenly through narrow tubes coated in catalyst, which enables close contact between catalyst and reagents without the need to introduce unpredictable turbulence for mixing, as used in many current systems. This hugely reduces waste and improves efficiency. The design of the system uses special surface coatings and a unique fluid propulsion method to achieve this, even in larger-scale applications.
The ReactoMod™ modular chemical reaction system has, as its core premise, the use of identical equipment during the process development cycle from research through to commercial production. Each ReactoMod™ element may be delivered using additive manufacturing techniques and isadaptable for use in both reactor and reactive-distillation mode, allowing for versatile continuous processes to be not only researched, but also put into immediate production by scaling out the equipment. The reaction modules are interchangeable, allowing the flexibility to research different configurations of catalyst and temperature profile unknown by Cutting Edge Products Group Ltd in any other system.
Each component of the system uses mature, proven technology, thus reducing technology development risk. The required proof of concept development has a suite of clearly defined program tasks with all required resources already identified. The amalgamation of proven technology relies on being able to demonstrate reactions taking place in an extended laminar flow regime that is postulated to be achievable through a combination of surface coatings and novel method of fluid propulsion.
An assembled ReactoMod™ system diagram is available on request.
ReactoMod™ is a trademark © Cutting Edge Products Group Limited 2025 - 2026