Process Intensification (PI) based on Flow Induced Phase Inversion (FIPI) phenomenon is reviewed briefly. The relationship between PI and process miniaturization through micro-reactor technology is considered in terms of micro-reactors and phenomenon based process intensification. The significance of FIPI in micro-reactor technology is considered in more detail. In order to achieve phenomenon based process intensification, it is necessary to conduct processes in micro-scale which provides extended surface area and enhanced selectivity through the interactions between the reactants / products and the micro-reactor environment. Strong interactions can be achieved by providing specific chemical functionality, surface area and accessibility within the micro-environment. These conditions are achieved by using nano-structured micro-porous polymers or metals with controlled chemical structure in which arterial pores provide accessibility and nano-pores provide surface area and functionality. We examined the preparation of sulphonated micro-cellular PolyHIPE Polymers prepared through a High Internal Phase Emulsion (HIPE) polymerization route and subsequently sulphonated using sulfuric acid which is already present within the pores of the micro-porous polymer. In the preparation of such polymers, FIPI is used to control the pore size and prevent the emulsion separation during polymerization as a result of sulfuric acid presence. PolyHIPE Polymers were also used as template in the preparation of nano-micro-porous metals/alloys which can be used as intensified catalyst or catalyst support. These catalysts also provide accessibility for the reactants and products through the arterial micro-pores connecting the nano-pores which provide catalytic activity and surface area.
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