DESC:FIELD OF THE INVENTION
The present invention relates to a multi-orifice oscillatory baffled reactor in which perforated baffle plates are surrounded by two layer of spiral coils to enhance turbulence and thereby overall mass and heat transfer.
BACKGROUND OF THE INVENTION
Oscillatory baffled reactors (OBRs) have been used to provide a reactor which promotes mixing without the use of stirrers or turbulent flow within the reactor. OBRs usually take the form of an elongated vertical or horizontal tube containing a number of baffles spaced along the tube. The baffles are usually plates which partially obstruct the internal cross-section of the tube, and include one or more orifices/holes for the passage of fluid. It is well known that if a fluid flowing through the tube is oscillated or pulsated, presence of the baffles causes the formation of vortices within the liquid, thereby providing an excellent mixing mechanism (Venturi Effect – ‘Vena Contracta’) without the use of stirrers. The most common OBRs include single orifice baffles equally spaced along the length column reactor. Each baffle is a plate containing a single, central orifice. However, as single-orifice OBRs are having scaled up limitations, beyond a certain point the advantageous mixing effects cannot be achieved and therefore different baffle geometries, additional internals and their accommodation techniques within column was remains researchers key interests since years.
WO2016009177 discloses a multi-orifice oscillatory baffled reactor, which comprises a reactor tube, a baffle within the reactor tube, the baffle defining a plurality of orifices, a gas source having an outlet within the reactor tube.
US8338070 discloses an oscillatory flow continuous reactor comprising one tubular member possessing one entry port, one outlet port, and a plurality of baffles, the baffles including one or more orifices disposed at spaced apart intervals along an interior space of the tubular member.
The reported OBRs have external jacket for heat transfer which has a lower heat transfer performance. OBR design reported in the prior art has heat transfer area about 20 m2/m3 ? 30 m2/m3. The multi-orifice OBRs of the present invention provides a promising solution to the problems associated with existing reactors. Accordingly, the present invention provides OBR with plurality of multi-orifice baffle with different size and two layers of internal concentric cooling coils which allows scalable mixing effects from laboratory to industrial scale and facilitates to improve heat transfer and mass transfer which enables to conduct fast and exothermic chemical processes - with a low residence time (RT) and narrow residence time distribution (RTD).
SUMMARY OF THE INVENTION
A first aspect of the invention is an oscillatory baffled reactor (OBR), comprising; at least two different types of equi-spaced multi-orifice baffles and at least two layer of spiral coils.
Another aspect of the invention is an oscillatory baffled reactor (OBR), comprising; vertical column reactor; equi-spaced at least two different types of multi-orifice baffles within the column reactor tied with internal support ‘tie rod’, at least two layer of spiral coils, and reciprocating piston pump and oscillatory means which, during use, provide oscillatory flow of a fluid relative to the static baffles.
In another aspect, a multi-orifice oscillatory baffled reactor may include plurality of baffles within the column reactor with 50 to 100 number of orifice having 4 mm to 8 mm diameter. A multi-orifice oscillatory baffled reactor may include plurality of baffles within the column reactor with two different sizes such as baffle type A with 50-80 numbers of orifice having 6-8 mm diameter and baffle type B with 70-100 numbers orifice having 4-6 mm diameter.
In another aspect, a multi-orifice oscillatory baffled reactor includes at least two layer of internal cooling spiral coils, which increases total interfacial area of contact from 60 m2/m3 to 100 m2/m3 of a single OBR column, more preferably 90 m2/m3 to 100 m2/m3.
DETAILED DESCRIPTION OF INVENTION
In one of the embodiment of the present invention an oscillatory baffled reactor (OBR) comprising; vertical column reactor; multi-orifice baffle plates/discs mounted inside column & tied with support rods, cooling spiral coils, and a reciprocating piston oscillator and oscillatory means which, during use, provide oscillatory flow of a fluid relative to the static baffles.
The use of a multi-orifice baffle in the OBR allows the reactor to be scalable, such that it may be used in both small to medium scale applications (laboratory, households, small wastewater treatment plants and hospitals) and large scale industrial applications.
Preferably, the reactor tube contains a plurality of baffles, each baffle defining a respective plurality of orifices and having a free open area of up to 25%. An OBR having two or more baffles provides one or more inter-baffle regions where radial mixing is strong and vortices are generated. The trapping of microbubbles generated due to oscillatory flow is therefore more effective, since it offers high interfacial area of contact for heat and mass transfer.
The number of baffles and number of holes/orifice in each baffles within the reactor is not particularly limited and depends upon the dimensions of the column reactor.
Any number of baffles may be employed within the reactor provided that the appropriate amount of radial mixing is produced. It will be clear to the skilled person that the exact number of baffles used within the reactor tube will depend on its design including, internal diameter & the length of the tube being used. Thus the number of baffles within the column reactor may be chosen accordingly.
Alternatively, the baffles may be spaced according to a non-regular sequence. The baffles may also be randomly spaced along the length of reactor tube. The multi-orifice oscillatory baffled reactor may have spacing between two consecutive baffles 0.5 to 0.75 times of column internal diameter.
An inter-baffle spacing within this range provides the optimal inter-baffle region size to achieve the necessary trapping of the microbubbles produced, leading to an increased gas hold-up, increased bubble residence time within the reactor tube and therefore enhanced gas utilization & efficiency.
OBR design which is available in the prior art is having the baffles designed so as to provide a close fit with the internal wall of the reactor tube. In other words, the diameter of the baffles may be substantially equal to the internal diameter of the reactor tube such that little or no fluid may pass between the outer perimeter of the baffle and the internal wall of the reactor tube. When such a close fit is provided, the fluid dynamics within the column reactor may be better controlled and predicted.
In one of the embodiment, the present invention provides baffle close fit by blocking of some circumferential area of column diameter by inserting a bundle of internal coils, to provide area of heat transfer and also serve as baffles.
All baffles within the OBR may be of identical or different design. All baffles may have the same baffle free open area and the same number, size and distribution of orifices. Furthermore, the baffles may all be manufactured from identical material with identical physical properties. Alternatively, the design of an individual baffle may differ from the design of other baffles within the column reactor. For example, the distribution of orifices in the baffle may be different, although and other parameters may be the same.
In one of the embodiment, the baffled may be specifically designed having two different types of orifice baffles such as different diameter and/or different orifice size. Further, each orifice is equally spaced and can alternatively enhance expansion and contraction phenomenon of mixing. It is a meso scale mixing which helps to improve liquid-liquid and gas-liquid mass transfer. During upward pressurized liquid motion, propagating liquid creates effects of ‘vena contracta’ – through orifice, which enables intimate contacts of liquid or gas-liquid streams.
In the multi-orifice oscillatory baffled reactor, the average number of orifices per baffle may be from 2 to 1500 e.g. from 5 to 1000, or from 5 to 750 or from 5 to 500 e.g. from 5 to 250. More preferably, the average number of orifices per baffle may be between 10 to 100.
In one of the embodiment, a multi-orifice oscillatory baffled reactor may include plurality of baffles within the column reactor with 50 to 100 number of orifice having 4 mm to 8 mm diameter. The OBR has 19 numbers of perforated baffles of two different types A and B. Baffle type ‘A’ have 50-80 orifice of 6-8 mm diameter and baffle type ‘B’ have 70-100 orifice of 4-6 mm diameter. However, the skilled person will be aware that the selection of the average number of orifices per baffle depends upon diameter of orifice and diameter of reactor and hence the total cross sectional area of the baffle.
The baffles may be manufactured from any suitable rigid material. Examples of suitable materials include stainless steel, acrylic polypropylene and PVC. The baffles may have a laminate structure comprising a plurality of layers sandwiched together. For example, a baffle may be constructed by sandwiching a suitable rigid polymer between two stainless steel layers. The central rigid polymer layer may be polypropylene or solid metal plates.
The baffles may be produced by any suitable method, including machining from sheet material, lamination or 3D printing.
The baffles may be supported within the OBR by suitable supporting means which may fix the position of the baffles relative to the column reactor. The supporting means may fix the position of the baffles relative to one another in such a way that it cannot change its position and alignment during the fluid oscillating motion.
Alternatively, where oscillation of the baffles rather than the fluid is desired, the supporting means may connect all baffles together and to the oscillatory means, such that all the baffles may be oscillated simultaneously.
In one of the embodiment, the supporting means may be tie rod(s) which connects all baffles together. The tie rod may also be connected to the column reactor, or the oscillatory means. The tie rod may be a fixed within the column reactor, passing through and connected to each baffle. The tie rod may be present in concentric circle of coils. The tie rod may be made from any suitable rigid material. Suitable materials include stainless steel.
In one of the embodiment, to enhance the heat transfer area internal spiral coil can be provided in addition to external jacket. A jacket has a lower heat transfer performance than an internal spiral coil as there will be a lower process side heat transfer coefficient, usually have a greater wall thickness, and a smaller surface area. It also require a higher service utility flow. The provision of two layer of spiral coil according to Figures provides several process advantages like effective heat transfer than the OBR with jacketed or single coil.
In one of the embodiment, two layer of internal concentric cooling coil increases the interfacial area of contact up to 80 m2/m3 to 100 m2/m3. More preferably up to 95 m2/m3. This can be beneficial to improve heat transfer which enables to conduct fast and exothermic chemical processes with a low residence time. Further, it also participates in creating turbulence in addition to perforated baffle discs.
In one of the embodiment, an arrangement of baffles within center of OBR column is in concentric circle of coils using a specific design tie rods.
In one of the embodiment, the oscillatory movement (Sinusoidal Flow Pattern) in the flow reactor is provided using reciprocating piston pump/ mechanical oscillator. The upwards and downwards strokes using piston generates oscillation to the reaction mass for efficient mixing. The oscillation frequency is ranging from 10 -150 strokes per minutes, preferably in the range of 60-120 strokes.
In one of the embodiment, a reciprocating device has crank & shaft arrangements. The diameter of shaft is about 200 mm and length of piston stroke is about 150 mm. The normal operating oscillation frequency is about 2 Hertz, which is variable and controllable potentiometrically. The device is having a peak piston velocity of about 1.88 m/sec and peak oscillation acceleration of about 23.68 m/sec2 which, ultimately results in maximum force due to oscillation is of about 2.0 kN. The hydraulic pressure created by oscillation is about 0.95 barg (un-baffled), while experimental pressure created by oscillation is observed about 0.45 barg (baffled). It indicates that an average pressure drop due to submerged (perforated baffles & internal coil) is about 0.5 barg (baffled).
The oscillatory means may be connected to a servo-hydraulic system which imparts the oscillatory motion.
Alternatively, any suitable means for providing oscillatory motion may be provided, such as a combustion, wind, solar powered motor, electro-mechanical or ultrasonic devices.
The oscillatory means may be capable of providing sinusoidal oscillatory motion. The oscillatory means can be controlled to produce a desired frequency and amplitude of fluid oscillation and/or baffle oscillation. The result is movement of fluid relative to the baffle through the baffle orifices, which creates the strong radial mixing in the reactor tube, particularly in the inter-baffle region when a plurality of baffles is present. The combination of oscillation and the specific baffle design in the OBR lead to the production and trapping of microbubbles within the reactor tube.
In general an OBR column should offer a good plug flow behavior and not a mixed flow behavior. This is required to avoid back mixing of flowing fluid through column and thereby controlling quality and productivity of product. In general more numbers of baffle arrangements along the length of reactor or alternatively more numbers of orifices within each baffle plates or alternatively smaller numbers of orifice size, can preferably offering a good PFR behavior as a part of ideal fluid hydrodynamics. Baffle’s – orifice/hole size, pitch arrangement and inter baffle clearance are to be effectively modelled and skillfully designed/selected in order to avoid bubble coalescence and thereby lowering mass transfer area.
An OBR can also be designed by placing perforated baffles in order by varying it’s inter baffle spacing along vertical or horizontal length. As example - Initial (50-70 %) baffles with more spacing (0.75 times internal diameter), While later or end (remaining 30 – 50 %) baffles with lower spacing (0.25 to 0.5 times internal diameter) and preferably these with more orifice or smaller diameter orifice. These kind of construction supports to produce comparatively more plug flow behavior especially on later part of OBR reactor. It is useful for those chemical reactions, where reaction kinetics is logarithmically dropping at ending states, due to mass transfer resistances.
The column reactor may be fabricated from any suitable material. Suitable materials include rigid plastics materials such as acrylic, PVC or polypropylene, or metallic materials such as steel of various grade like SS 304 , 316 , 904, 916 etc., including hastelloy of various grades like HC-22 , HC-276 , B2 or B3 grade material, or glass. The column reactor may be made from a transparent material like poly acrylic - to provide for ease of visual monitoring.
The column reactor may be sealed at both ends to prevent the unwanted leakage of fluid during operation of the OBR. The column reactor may define an opening which acts as a fluid inlet. The opening may be sealable my means of a valve. The column reactor may define an opening which acts as a fluid outlet. The opening may be sealable my means of a valve. It should also provide with process vents or necessary safety devices as per process requirements.
The column reactor may be of a wide range of dimensions depending on the intended application. The size of the column reactor may range from a size suitable for small scale (e.g. laboratory) use, up to sizes suitable for large scale (e.g. industrial water treatment) use. Clearly, the dimensions of all other components of the reactor will also vary accordingly to correspond with the dimensions of the reactor tube. For example, a suitable size of baffle will be selected depending on the size of the reactor tube. The multi-orifice oscillatory baffled reactor may include a reactor tube with an internal diameter of at least 20 mm and up to 250 mm.
The column reactor of the multi-orifice oscillatory baffled reactor may contain between 8 to 10 baffles, each baffle having a free open area of up to 25% and the inter-baffle spacing being between 25 mm and 100 mm, wherein the hydraulic diameter is between 50 mm and 200 mm, the hydraulic diameter being defined as above.
The oscillatory means may be adapted to oscillate at a frequency at least 20 Hz. preferably at least 10 Hz. More preferably at least 5 Hz.
The oscillatory means may be adapted to oscillate with a center-to-peak amplitude of at least 200 mm, preferably at least 175 mm, more preferably at least 150 mm.
In another embodiment OBR as per the description can be is used in the manufacturing of any active pharmaceutical ingredient and their intermediates by continuous process. The OBR as per the description can be is used in the manufacturing of active pharmaceutical ingredient including but not limited to Pregabalin, Abemaciclib, Adapalene, Agomelatine, Alogliptin Benzoate, Apixaban, Aripiprazole, Asenapine maleate, Azilsartan, Acalabrutinib , Afatinib, Amantadine, Apremilast, Axitinib, Azacitidine, Azithromycin, Bempedoic acid, Bimatoprost, Brexpiprazole, Bumetanide, Bupivacaine, Binimetinib, Bosentan, Bosutinib, Brivaracetam, Bupropion, Calcium gluconate, Canagliflozin, Candesartan, Carfilzomib, Celecoxib¸ Cilostazol, Clevidipine, Clonidine, Cabozantinib, Dabrafenib, Darifenacin, Darolutamide, Dexlansoprazole, Donepezil, Dorzolamide, Duloxetine, Dabigatran, Dapagliflozin, Dapsone, Dasatinib, Deferasirox, Deutetrabenazine, Dronedarone, Empagliflozin, Enzalutamide, Erlotinib, Erythromycin, Etoricoxib, Etrasimod, Febuxostat, Famotidine, Felodipine, Fenofibrate, Fenofibric acid, Fingolimod, Fluoxetine, Ferumoxytol, Fesoterodine, Fluphenazine, Fulvestrant, Gefitinib, Hydrochlorothiazide, Ibrutinib, Illoperidone, Infigratinib, Ivabradine, Irbesartan, Iron sucrose, Ivacaftor, Ivosidenib, Ketorolac, Larotrectinib, Lercanidipine, Linagliptin, Losartan, Lacosamide, Lamotrigine, Leflunomide, Lenalidomide, Linezolid, Lotilaner, Lurasidone, Macitentan, Memantine, Metoprolol, Mexiletine, Modafinil, Methomyl, Methotrexate, Metolazone, Minodronic acid, Niraparib, Nitrofurantoin, Nelarabine, Nisoldipine, Olaparib, Olmesartan, Oseltamivir, Obeticholic acid, O-desmethy Venlafaxine, Osimertinib, Pirfenidone, Pramipaxole, Prasugrel, Palbociclib, Pinaverium, Ponatinib, Prucalopride, Quetiapine, Ribociclib, Rifaximin, Roxithromycin, Rabeprazol, Riociguat, Rivaroxaban, Rivastigmine, Roflumilast, Ropinirole, Ruxolitinib, Sacubitril, Valsartan, Selexipag, Sorafenib, Silodosin, Solifenacin, Suvorexant, Tegaserod, Temazepam, Teriflunomide, Tipiracil, Topiramate, Trifluridine, Tadalafil, Telmisartan, Tepotinib, Ticagrelor, Trametinib, Venetoclax, Viloxazine, Vardenafil, Venlafaxine, Vilazodone, Vildagliptin, Vortioxetine, Warfarin, Zolmitriptan, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure-1: Oscillatory Baffled Reactor (general schematic arrangements)
Figure-2: Geometrical Arrangements of OBR Column with Internals
Figure-2A: Bottom section (Inlets) & Figure-2B: Top section (Outlet)
Figure-3: Geometrical Arrangements of OBR Column with Internals (side view)
Figure-4: Geometrical Arrangements of OBR Column with Internals
Figure-4A: Overall Top View & Figure-4B: Vertical sectional Views
Figure-5: Geometrical Arrangements of OBR Column with Baffles
(Top View)
Figure-6: Schematic Drawing of Column with (Baffles + Tie Rods)
Figure-7: Schematic Drawing of Mechanical Oscillator for OBR Column
Figure-8: Schematic arrangement of OBR Columns connected in series for multiple unit operations & applications

DETAILED DESCRIPTION OF DRAWING
Referring to Figure-1, the OBR (Oscillatory Baffled Reactor) includes a vertical metallic column having different elements. The main shell and other elements of OBR column is fabricated with material of construction - ‘Stainless Steel Grade - 316’ or equivalent, which can be useable for wide range of chemical processing.

The Main shell 1, of OBR is having ?200 mm internal diameter and about ?3500 mm tangent to tangent vertical height. The thickness of shell is designed in such a way that, it can withstand to operating conditions such as at about 150 °C temperature and about 6 barg internal pressure. With an available dimensions & geometry of column, a single OBR column can offer approximate working overflow volume of 75 liters. The effective baffled height to baffle disc diameter ratio is about 25.
The main shell is surrounded & welded with an external jacket 2 to circulate service utility fluids in order to control the desired process temperatures.
The arrangement of internal coil 3A & 3B as referred in Figure-1 and further describe in Figure-2 with a schematic model drawing in Figures-2A and 2B. Since the heat transfer area of an external jacket is limiting especially for chemically fast and exothermic reactions, in present invention the OBR column is facilitated with inserting a special design of two numbers of concentric diameter spiral type of Inner cooling coils (3A & 3B). Which can provide very high heat transfer area and also offers very high heat transfer co-efficient - since the velocity of service utility fluid must be quite higher than that of external jacket. The combined arrangement as depicted in Figure-3 and Figure-4 [external jacket + internal coil] provides about 100 m2/m3 of interfacial area of contact for efficient heat and mass transfer, which is almost 10 times higher than that of conventional batch stirred reactor.
The key element of OBR design is perforated baffles type 4A and 4B. These two different types of baffles have disc diameters of 100 mm and 80 mm respectively. The detail description of these baffles is given in Figure-5, wherein Type A baffles have about 60 numbers of orifice having 7 mm diameter, which arranged in 10.5 mm of triangular pitch and Type B baffles have about 87 numbers of orifice each having 5 mm diameter, which arranged in 7.5 mm triangular pitch. There are total 20 numbers of both Type A and B baffles (10 each) which are alternatively arranged along the vertical height of column and equi-spaced (about 125 mm clearance). The design of baffles are selected such that, it preferably avoid bubble coalescence and bi-directional back mixing. The effectiveness of design offers about 23 % free open area for gas-liquid flow.
Both types of baffles are vertically aligned and fixed on a central support of tie rods 5, which are solid stainless steel rods placed parallel to height of column. The bolting arrangements are made to provide flexible, easy to open for maintenance and cleaning. The arrangements are sturdy enough to withstand dynamic load against oscillation arises due to fluid motion. As shown in Figure-6, the baffle plates and tie rods are in a perpendicular plane in order to provide uniform smooth flow.
The OBR column is equipped with two side stream entry 6A and 6B (approximate diameter 25 mm), above the top flange of oscillator for charging of liquid or slurry or gas from the bottom of column. Both charging nozzles are further attached on upstream side with NRVs (Non Return Valve) and a flow meter on each side in order to dose metered fluid inside column.
A process overflow nozzle 7, is placed on top of OBR column at height equivalent to 75 liters working volume. It is inclined downward about 10 degrees (approximate diameter 25 mm), which enables smooth and continuous discharge of processed liquid or slurry. An extra space (freeboard dis-engagement space) of about 150 mm is kept above this overflow nozzle and below vent hole to accommodate frothing or foaming generated by process.
The OBR is also facilitated with process vents 8, and/or more additional vents to maintain safety of column against over pressurization. This vents (diameter about 25 mm) are further equipped with protection devices like safety valves or rupture discs or in combinations. The OBR is also instrumental with two hydraulic pressure gauges (PG) 9A and 9B, at bottom & top of column respectively. It indicates the pressure induced by mechanical oscillator to the flowing fluid against static head of liquid. The fluid temperature in OBR column at bottom and top are measured by using RTDs 10A & 10B (TI – Temperature indicator), respectively, which are inserted through thermos pockets. Different parts or section of OBR columns are connected by placing a glass spool piece - sight/view glass 11A & 11B to visualize fluid flow and to ensure the intensity of mixing at different oscillating conditions. It was fabricated by using toughened borosilicate glass material, which is further surrounded by a protective metal safety cage to mitigate against breakage.
Mechanical Oscillator 12, and its schematic drawing Figure-7 is stationed at most bottom part of OBR column. Its top flange and most bottom flange of column is concentrically bolted to a correct alignment. It is a reciprocating device having crack & shaft arrangements. It is having hollow Shaft 14, having diameter of about 100 mm and a hollow Piston 13, with diameter of about 200 mm and stroke length of about 150 mm. The oscillatory sinusoidal moment of shaft is created by using a hydraulic gearbox (Ratio – 10:01) coupled with an electric Drive induction motor 15, of 10 Horse Power. The normal operating oscillation frequency is about 2 Hertz; however it is variable and controllable potentiometrically. With this available configuration, the device is having a peak piston velocity of about 1.88 m/sec and peak oscillation acceleration of about 23.68 m/sec2. This, ultimately results in maximum force due to oscillation is of about 2.0 kN. Due to which, the hydraulic pressure created by oscillation is about 0.95 barg (Un-baffled), while experimental pressure created by oscillation is observed about 0.45 barg (baffled). It indicates that an average pressure drop due to perforated baffles is about 0.5 barg (baffled). The piston block is externally wrapped (sealed) with a polymeric & elastic gland material in order to avoid seepage of fluid due to hydrostatic head. The piston alloy is also hard chromed & annealed perfectly in order to maintain its hardness against cyclic erosions. The base frame of mechanical oscillator is also fixed with an anti-vibration pad material i.e. Rubber, in order to control vibration frequency below 0.5 mm.
All the drawings and figures presented here are NTS (Not to Scale) and mentioned dimensions are in milli-meter until & unless specified.
The said OBR column design of present invention improves heat transfer and mass transfer with baffles, two layer of internal cooling coils and special tie rod arrangement which enables to conduct fast and exothermic chemical processes in continuous mode of operation with a lower residence time.
OBR column design of present invention provide heat transfer area of about 80 m2/m3 to 100 m2/m3 because of the presence of two concentric layer of internal cooling coils; different type of perforated baffles provides efficient mixing by creating turbulence; meso-scale mixing so efficient for handling gases and solid particles; it can operate in fed batch mode and also in continuous mode of operation; effective mixing even at low velocity responsible for good heat and mass transfer applications; mixing behavior is Plug Flow (PFR), estimated by simulated RTD (residence time distribution) studies using CFD (computational fluid dynamics) approach. An indicative average figure of ‘Number of tank in series’ is equal to 18 is observed, which indicates a reasonable plug flow behavior and minimum back mixing (CSTR – continuous stirred tank reactor) behavior. The design can be further upgraded by inserting multiple numbers of perforated plates or alternatively reducing hole size (diameters).
The OBR design according to the Figure 1-8 can be is used in the manufacturing of any active pharmaceutical ingredient and their intermediates by continuous process. The OBR design according to the Figure 1-8 allows to conduct any chemical reaction, which are specifically exothermic reaction.
Examples:
Example-1: Behavior of Plug Flow
The commercial design of OBR column was tested with RTD (Residence Time Distribution) studies by using CFD (Computational Fluid Dynamics) simulation snap shot approach, where it indicates about 18 numbers of average CSTR (Continuous stirred tank reactors) in series/sequence , at its maximum design velocity of about 0.3 m/sec. Which shows that the performance of said design is equivalent to multiple stirred batch tanks in series and thereby Plug Flow.

The advantage of more tanks in series gives a plug flow behavior ( but not back mixed blow) advantages in terms of avoiding back mixing of reactants , formation of hot spots, blind spots of reactants and stagnancy of materiel in reactor.
Example-2: Equivalency with Batch Reactor
A continuous said design of OBR have a capability of intense fluid mixing behavior. A CFD studies carried out to estimate mixing time ?95 is about 4.5 seconds (75 Ltr. Volume, 180 LPH flow rate and 120 Strokes/min), if similar or equivalent mixing time ?95 is required to be achieved (4.5 seconds) in batch reactor - it needs to stir the content of a conventional batch reactor at rpm not less than 1000 (75 Ltrs, Pitched Blade Agitator).
Example-3: Versatility of application in manufacturing
The said design can be useful as a single reactor or in multiple arranged in series Figure-(8) to conduct a set of complete manufacturing process. It can also be used for continuous precipitation or continuous crystallization or extraction kind of unit operations.
The OBR column can also be integrated with different type of PAT tools like conductivity or pH probe for in process analysis, Particle size or Vision probes for crystallization or precipitation operations, UV Lamps/LED or Photocells for photochemical transformations, Ultra-Sonotrodes for specific chemistry applications, and React IR or NIR or Raman probes for inline reaction concentration measurements.
Example-4: Linear Scalability to Commercial Scale
The scalability of OBR design can be assessed by observing below parameters estimated for Laboratory, Pilot and Industrial scale columns.
Parameters Lab Pilot Commercial
OBR Capacity (Ltrs) 3.5 7.6 160
Internal Diameter (mm) 50 80 200
Flow Rate (LPH) 2.7 7.2 170
Scale Up Criterion
Residence Time (Mins) 77.77 63.33 58.23
Baffled Height / Diameter 45 46.67 48.02
% Open orifice Area 22.00 23.11 23.79
Ratio (NRe/NReo Hole Reynolds No.) 1290.38 1196.17 1235.18
% Baffle Cross Area 0.6 0.562 0.565
Baffle Discs Ratios (%) 1.56 1.5 1.41
Effective interfacial heat transfer area (m2/m3) 80 130 94
Strouhal number (NSt) to estimate effective vortex propagation relative to the OBR diameter 0.053 0.053 0.106

,CLAIMS:We Claim:

1. An oscillatory baffled reactor (OBR), comprising at least two different types of equi-spaced multi-orifice baffles and at least two layer of spiral coils.
2. A multi-orifice oscillatory baffled reactor as claimed in claim 1, further comprising a column reactor and oscillatory means which, during use, provides oscillatory flow of a fluid relative to the baffle.
3. A multi-orifice oscillatory baffled reactor as claimed in claim 1, wherein the multi-orifice baffle has number of orifice varies from 50 to 100 and size of the orifice vary from 4 mm to 8 mm.
4. A multi-orifice oscillatory baffled reactor as claimed in claim 1, wherein the provision of two internal cooling coils increases total interfacial area of contact about 100 m2/m3 of a single OBR column.
5. The multi-orifice oscillatory baffled reactor as claimed in claim 1, wherein the oscillatory means is provided using a reciprocating piston.
6. The multi-orifice oscillatory baffled reactor as claimed in claim 2, where in column reactor is vertical column reactor having at least 200 mm internal diameter and about 3500 mm vertical height.
7. The multi-orifice oscillatory baffled reactor as claimed in claim 1, wherein each baffle has a free open area of up to 25%.
8. A multi-orifice oscillatory baffled reactor as claimed in claim 1, is used in the preparation of active pharmaceutical ingredient and their intermediates.
9. A multi-orifice oscillatory baffled reactor as claimed in claim 1, is used in the manufacturing of active pharmaceutical ingredient and their intermediates by continuous process.
10. A multi-orifice baffled reactor substantially as described with reference to, and as illustrated in, Figures 1, 2, 3, 4, 5, 6, 7 and 8.