COSTA™ Technology

COSTA™ Technology

The developed COSTA™ technology is the cornerstone of a range of Creaflow's flow reactors. The name originates from its three distinct features: Continuous processing in a linear plate flow reactor; the use of a superimposed Oscillatory flow regime; and the STAtic mixing elements located in the process channel.

This combination creates a pulsating split-and-recombine flow pattern, which results in an intense and tuneable mixing, independent of the net flow rate, while plug flow behaviour is astoundingly improved. Critical process characteristics such as mass- and energy-transfer, residence time distribution and pressure drop are not influenced by the broadening of the linear process channel, so processes can easily be scaled.

Intense & tuneable mixing independent of net flow rate

The synergetic combination of the static mixing elements and superimposed pulsatile flow, allows intense mixing at all flow rates. As a result, chemical reactions that require longer residence times (i.e. low flow reactions) can be run in a continuous one-pass operation with no need for recirculation , while ensuring excellent control over the residence time distribution. In addition, the two novel process parameters (i.e. pulsation frequency & amplitude) allow you to further optimize your process.

Performant for demanding (multi-phase) processes

COSTA™ Technology can be applied to the scale-up of demanding multi-phases processes, as it allows the effective mixing of immiscible liquids and guarantees the processing of solid particles in suspension at any flow rate. The effective handling of suspensions containing, for example heterogeneous (photo)catalysts, insoluble APIs or inorganic bases truly opens new avenues in scalable flow (photo)chemistry.

Excellent temperature control

As addition to the excellent mixing provided, heat is effectively dissipated through-metal via the extensive static mixing element surfaces, and enables on-demand temperature control to operate your chemical process at complete iso-thermal conditions.

Improved plug flow profile

While for millimetre and submillimetre dimensioned flow reactors, laminar flow is dominant, the pulsatile flow acquired from the COSTA™ Technology, unlocks unique flow characteristics. As an effect of the pulsation in combination with the static mixing elements, the laminar (i.e. parabolic) velocity profile of your flow field is minimized, and with the optimized amplitude and frequency for your specific process, the flow boundary effect is eliminated, resulting in an improved residence time distribution (RTD), i.e. a plug flow profile for the reactor.

Linear scalability from lab to production

The developed COSTA™ technology permits a single cycle scale-up strategy by simply widening the process channel while all the crucial process characteristics - process path length, irradiation properties, mass and heat transfer, residence time distribution and so on – remain unaffected.