Custom automation for enhanced catalysis research

Custom automation has the potential to transform complex research and manufacturing processes by delivering tailored solutions to meet specific requirements. The Swiss Cat+ laboratory sought to enhance efficiency and precision in their catalysis research, aiming to automate crucial aspects of their workflow. With the support of Advanced Microfluidics’ engineering services, Swiss Cat+ has been able to continuously monitor and multiplex their catalytic reactions online, ensuring their processes are more reliable, scalable, and scientifically robust.

The Swiss Cat+ initiative, a collaboration between ETH Zurich and EPFL, is at the forefront of catalysis research innovation, leveraging advanced automation to achieve higher levels of accuracy, productivity, and operational efficiency. This customer case explores how Swiss Cat+ successfully tackled the challenges of their Optifire project with integrated solutions that enable seamless and efficient monitoring of complex catalytic reactions.

Challenge

For the Optifire project, Swiss Cat + lab faced challenges in automating catalytic reaction monitoring. They were specifically missing a link between the instruments that facilitated the chemical reactions and their Bruker 400 MHz benchtop NMR systems, which are used for the thorough examination of reaction mixtures. The goal of this project was to achieve complete automation, eliminating reliance on traditional, manual intervention methods, which are often prone to inefficiencies, inconsistencies, and increased risks that hinder productivity.

Swiss Cat + lab needed a solution that could seamlessly integrate these components, automate data collection, and provide real-time control over reactions. Additionally, they required extensive testing to ensure the reliability of the automation process, while also aiming to increase productivity and reduce risk. To address this gap, they looked for custom automation systems that could facilitate complex processes.

Introduction of the Automated Low Volume Multiplexing Fluidic System

To meet the needs of automated catalytic reaction monitoring, Swiss Cat + lab implemented the Advanced Low Volume Multiplexing Sampling System from Advanced Microfluidics. This powerful system connects multiple reactors to a single analytical platform, enabling high-precision monitoring of reactions across multiple streams in real-time. This approach revolutionizes catalytic reaction workflows by enhancing data collection and allowing for comprehensive, accurate, and efficient monitoring of all key parameters.

The system’s flexibility extends across a wide range of catalytic reactions, providing researchers with a scalable and adaptable tool that supports both academic and industrial applications. By integrating directly into existing platforms, this system ensures a seamless connection between all parts of the workflow, allowing researchers to focus on results rather than operational complexities.

Our solution

Our custom automation system leverages cutting-edge engineering to provide a comprehensive, fully integrated solution that is tailored specifically to the needs of catalysis monitoring. This solution includes automated control, integrated data collection, and seamless management of reaction parameters.

The solution comprises:

• Automated multiplexing system: Our custom automation solution uses a multiplexing fluidic system that contains all valves, pumps, and selectors, and connects up to three reactors within a single analytical platform. This provides a robust solution for automated, real-time sampling and monitoring of reactions. This integration allows multiple reactions to be analyzed simultaneously, increasing throughput and providing higher quality data.
• Real-time data integration: By creating custom automation scripts and control systems, our team ensured that reaction parameters were collected and analyzed in real-time. This eliminated the inefficiencies and risks associated with manual sampling while increasing the accuracy of the results. Complex characterization, including infrared spectroscopy and mass spectroscopy, can be integrated into the data collection process, providing more detailed insights into reaction conditions.
• Custom automation systems and control systems: Our automated systems were designed to control and monitor reaction environments precisely. This included parameters such as temperature, pressure, and chemical composition, all managed through advanced automation control systems that streamline processes and enhance productivity. Automated sample preparation reduces risks, and the system can achieve up to 300 reactions per day at a 1 ml scale, compared to traditional methods. Additionally, the platform allows for testing on a 250 ml scale, providing flexibility for scaling experiments.
• Seamless integration with existing platforms: Our automation system was designed to integrate with existing instruments in the lab, allowing for a consistent and uninterrupted workflow. This reduced the need for manual handling and significantly minimized the risk of human error during sampling and data analysis. The platform is available to all researchers, promoting collaboration and innovation.
• Advanced analytical capabilities: Our custom solution connects with an automated nuclear magnetic resonance (NMR) for high-resolution analysis, as well as high-resolution ion mobility to provide information on molecular volume.

The system is composed of:

• 3 SPM (Industrial Programmable Syringe Pumps)
• 3 RVM (Industrial Microfluidic Rotary Valves) with a Distribution Valve
• 1 RVM with a Switch Valve

All components are integrated into an assembly that can be installed wherever the customer needs, providing flexibility in deployment.

Benefits of the AMF Multiplexing System

The custom automation solution provided by AMF offers a range of benefits that significantly enhance the efficiency and reliability of catalytic reaction monitoring:

• Custom automation and multiplexing: The ability to monitor multiple reactions in parallel using a multiplexing fluidic system ensures that researchers can gather extensive data from different experimental conditions simultaneously, allowing for deeper analysis and faster decision-making.
• Accuracy, predictability, and precision: With the custom automation system, the accuracy and predictability of the reactions improved, providing highly reliable data. This is especially critical in catalysis research, where even small deviations can significantly impact the results.
• Streamlined workflows: By automating processes such as sample purification and reaction monitoring, the AMF system significantly reduced manual labor. The result is a more streamlined workflow that allows researchers to focus on analysis and innovation.
• Enhanced data accuracy: With online Solid Phase Extraction (SPE) integrated into the workflow, the AMF system ensured that all samples reaching the analysis stage were purified and of high quality. This greatly improved the reliability of the data produced.
• Increased throughput: The custom automation system enables researchers to handle multiple reactions in parallel, significantly boosting productivity. This system is suitable for both research and industrial applications, making it an ideal solution for large-scale experimental setups.

Results

The implementation of the custom automation system in the Swiss Cat+ lab is anticipated to significantly improve the efficiency and reliability of catalysis research. While full deployment and feedback are still pending, the system is designed to automate key processes and integrate advanced control systems, enabling the Swiss Cat+ lab team to potentially:

• Increase productivity by reducing the time spent on manual operations and increasing experimental throughput using custom automation systems that support real-time monitoring.
• Enhance workflow efficiency through the use of advanced automation technologies that eliminate manual errors, reduce waste, and allow for better process control.
• Optimize reaction analysis with purified samples reaching the analytical equipments in real time, leading to improved data precision and accelerated discovery.

Applications

Swiss Cat + lab’s custom automation systems have been instrumental in advancing catalysis research across a variety of key applications. These systems can be employed in:

• CO2 Hydrogenation projects: Custom automation is used to monitor and optimize CO2 hydrogenation reactions. By integrating multiple reactors and ensuring real-time data integration, Swiss Cat + lab achieved a more rapid identification of optimal catalytic conditions, reducing experimental costs.
• Methane reforming reactions: In projects involving methane reforming, the AMF system’s custom automation capabilities allowed for seamless online sampling and analysis. The result was more precise data, faster optimization, and enhanced reproducibility.
• Photocatalysis optimization: The AMF system supported research into developing efficient photocatalysts by providing real-time monitoring and analysis of reaction kinetics, allowing researchers to evaluate catalyst performance effectively.
• Enzyme catalysis for biofuel production: Custom automation also played a role in optimizing enzyme-catalyzed reactions for biofuel production. The high-precision data obtained through this automation enabled researchers to optimize enzyme efficiency and improve biofuel yield.
• Oxidation reactions for fine chemicals: Swiss Cat + lab used custom automation to optimize oxidation reactions for fine chemical production. This led to higher yields, better reproducibility, and improved process control in a complex experimental setting.

Conclusion

The benefits of custom automation are extensive: it enables industries to improve productivity, enhance operational efficiency, reduce waste, be cost effective, and streamline complex processes through innovative automation systems. Swiss Cat +lab has implemented a comprehensive custom automation solution from AMF that integrates real-time monitoring, automated control systems, and precision engineering to meet the demands of advanced catalysis research.

To create a custom automation solution, our team of engineers offers design-build integration services that ensure every system meets the unique needs of our clients.

We are custom automation providers—Advanced Microfluidics (AMF) is dedicated to delivering high-quality custom automation technologies. Our custom automation technologies have applications in a wide range of industries. Whether it is to improve efficiency, reduce waste, or enhance operational capabilities, custom automation plays a critical role in achieving success.

Contact our experts by filling out the form below. We will provide detailed information on how AMF’s advanced microfluidic technology can be tailored to your specific needs, helping you stay ahead in your demanding field.