In the introductory part of the Master’s thesis we present continuous flow system, different approaches to continuous extractions and separations of two-phase fluids and give examples of real pharmaceutical continuous systems, including continuous hydrogenation and economic comparison of batch and continuous systems. Additionally, we present a number of (continuous) separation systems based on the gravitational force, semi-permeable membrane, centrifugal force and capillary pressure gradient. Continuous flow chemistry is a serious candidate for the replacement of traditional technologies for the production of active pharmaceutical ingredients, based on classis “batch” synthesis. The small volumes and large interfacial surface area of microreactors and microseparators present many advantages related to safety, optimization, productivity and efficiency of chemical reactions and isolations. In the traditional manufacturing of active pharmaceutical ingredients, each step is performed separately, including separation and purification step of the product or intermediate, which usually represents additional process step. Using flow chemistry however, it is possible to combine all process steps into one continuous, fully automated process. In the Master’s thesis we want to study and perform continuous extraction and separation of two immiscible liquids, by planning and making a microseparator from highly resistant material perfluoro alkoxy, suitable for use with aggressive chemicals. In the experimental part of the Master’s thesis we started with the sizing and optimization of existing model of microseparator. We used various simulations and the use of numerical tools (e.g. Lattice-Boltzmann method) to plan the base geometry of microseparators, which were later tested on a real extraction and separation model of active ingredient mycophenolate mofetil – MMF (product, soluble in organic phase, toluene) and salt of mycophenolic acid – MPA (starting material, soluble in water phase), using two-phase segmented flow and compared alternative and classical process for extraction and separation of selected pharmaceutical ingredients. Prototypes of microseparators made, represent a cost-effective alternative to existing continuous separation systems. Based on the results of the experimental work, we believe that these prototypes confirm the possibility of continuous separation of two-phase mixtures, based on the capillary pressure gradient.
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