Smart Microcontainers technology and its application in complex industrial processes

UDK: 541.124

DOI: 10.24887/0028-2448-2026-2-103-107

Key words: smart microcontainers (SMC), polymerization, microencapsulation, controlled mixing, Lewis acids, epoxidation

Authors: A.A. Papushkina (MEAC LLC, RF, Moscow); V.R. Kim (MEAC LLC, RF, Moscow); M.D. Kaplina (MEAC LLC, RF, Moscow); L.A. Alieva (MEAC LLC, RF, Moscow); A.V. Zamriy (MEAC LLC, RF, Moscow); N.P. Bezrukov (A.V. Topchiev Institute of Petrochemical Synthesis of the RAS, RF, Moscow); S.V. Antonov (A.V. Topchiev Institute of Petrochemical Synthesis) of the RAS, RF, Moscow; I.Z. Salikhov (Tatneftekhiminvest-kholding JSC, RF, Kazan); Y.M. Averina (D.I. Mendeleev Russian University of Chemical Technology, RF, Moscow); A.L. Maksimov (A.V. Topchiev Institute of Petrochemical Synthesis of the RAS, RF, Moscow); A.S. Sigov (Russian Technological University MIREA, RF, Moscow_

The article explores the potential of Smart Microcontainer (SMC) technology. The essence of the innovation is to create microscopic capsules that hold active reagents and release them in response to specific external signals - temperature change, pH, exposure to magnetic field or ultrasound. This real-time, point-to-point reaction control capability paves the way for overcoming limitations of modern chemical technology. Three practically significant areas of application are considered. The first is polymerization control, when SMC solve the critical problem of heat dissipation and temperature fluctuations, which enables not only to increase safety, but also to significantly narrow the molecular weight distribution of the final product. The second area is catalysis. Microencapsulation of highly active but sophisticated Lewis acids enables to create heterogeneous systems that combine the efficiency of a homogeneous catalyst with the ease of its recovery and regeneration. This dramatically reduces reagent consumption and minimizes toxic waste generation in processes such as Friedel-Crafts acylation. Particular attention is paid to olefin epoxidation processes, traditionally associated with high risks of thermal overclocking and low selectivity. Controlled release of hydrogen peroxide from microcontainers eliminates dangerous local overconcentrations, smooths exothermics, and suppresses unwanted acid-catalyzed epoxy ring opening. Thus, SMC technology represents an integrated approach that takes into account safety, selectivity, resource savings and ecology, puts SMC as the basis for the transition to smarter, more efficient and sustainable production processes in the future.

References

1. Sukhorukov G.B., Yerokhin V.V., Zamriy A.A., Viktorova N.V., Smart microcontainers: Transportation and recycling (In Russ.), Neft′ Rossii, 2019, November, pp. 61–63.

2. Zamriĭ A.V., Viktorova N.V., Smart microcontainers (In Russ.), Neftegazovaya vertikal′, 2019, no. 10, pp. 27–31.

3. Sigov A.S., Maksimov A.L., Antonov S.V. et al., Progress in Smart Microsontainers technology and new application points in oil and gas, petrochemicals and chemicals technology (In Russ.), Neftyanoye khozyaystvo = Oil Industry, 2025, no. 6, pp. 88–92, DOI: https://doi.org/10.24887/0028-2448-2025-6-88-92

4. Maksimov A.L. et al., Application of smart microcontainers in polymerization processes. Part 1 (In Russ.), Neftegazovaya vertikal’, 2021, no. 11, pp. 92–97.

5. Nguyen M.-T.T. et al., Mechanism of Friedel-Crafts acylation using metal triflate in deep eutectic solvents: An experimental and computational study, ACS Omega, 2023, V. 8, No. 1, pp. 271–278, DOI: https://doi.org/10.1021/acsomega.2c03944

6. Sartori G., Maggi R., Use of solid catalysts in Friedel−Crafts acylation reactions, Chem. Rev., 2006, V. 106, No. 3, pp. 1077–1104, DOI: https://doi.org/10.1021/cr040695c

7. Kobayashi S., Nagayama S.A., Microencapsulated Lewis acid. A new type of polymer-supported Lewis acid catalyst of wide utility in organic synthesis, J. Am. Chem. Soc., 1998, V. 120, No. 12, pp. 2985–2986, DOI: https://doi.org/10.1016/j.biombioe.2023.106950

8. Alamry K.A. et al., Ultrasound assisted microencapsulation of zinc triflate in polyethersulfone as an efficient regioselective catalyst for Friedel-Crafts acylation reaction, Polymer, 2019, V. 189, August, pp. 122–123, DOI: https://doi.org/10.1016/j.polymer.2019.122123

9. Nigussie G.Y. et al., An efficient H2O2-based propylene to propylene oxide (HPPO) reaction catalyzed by ZnO/ZnO2 materials, J. Mater. Chem. A., 2025, V. 13, No. 7, pp. 5261–5274, DOI: https://doi.org/10.1039/d4ta08256g

10. Yang J. et al., Review and perspectives on TS-1 catalyzed propylene epoxidation, iScience, 2024, V. 27, No. 3, pp. 1–46,

DOI: https://doi.org/10.1016/j.isci.2024.109064

11. Wu L. et al., In-depth understanding of acid catalysis of solvolysis of propene oxide over titanosilicates and titanosilicate/H2O2 systems, J. Catal., 2016, V. 337,

pp. 248–259, DOI: https://doi.org/10.1016/j.jcat.2016.01.028

12. Cheng C. et al., Study on reaction mechanism and process safety for epoxidation, ACS Omega, 2023, V. 8, No. 49, pp. 47254–47261, DOI: https://doi.org/10.1021/acsomega.3c07461

13. Achary P.G.R., Toropova A.P., Toropov A.A., Prediction of the self-accelerating decomposition temperature of organic peroxides, Process Saf. Prog., 2021, V. 40,

No. 2, pp. 1–10, DOI: https://doi.org/10.1002/prs.12189

14. Jiang J. et al., New thermal runaway risk assessment methods for two step synthesis reactions, Org. Process Res. Dev., 2018, V. 22, No. 12, pp. 1772–1781,

DOI: https://doi.org/10.1021/acs.oprd.8b00266

15. Yuan Z., Ni Y., Van Heiningen A.R.P., Kinetics of the peracetic acid decomposition: Part II: pH effect and alkaline hydrolysis, Can. J. Chem. Eng., 1997, V. 75, No. 1,

pp. 42–47, DOI: https://doi.org/10.1002/cjce.5450750109

16. Zhao X. et al., Preparation of peracetic acid from hydrogen peroxide, J. Mol. Catal. A Chem., 2007, V. 271, No. 1–2, pp. 246–252,

DOI: https://doi.org/10.1016/j.molcata.2007.03.012

17. Wai P.T. et al., Catalytic developments in the epoxidation of vegetable oils and the analysis methods of epoxidized products, RSC Adv. Royal Society of Chemistry, 2019, V. 9, No. 65, pp. 38119–38136, DOI: https://doi.org/10.1039/c9ra05943a

18. Turco R. et al., Epoxidation of linseed oil by performic acid produced in situ, Ind. Eng. Chem. Res., 2021, V. 60, No. 46, pp. 16607–16618,

DOI: https://doi.org/10.1021/acs.iecr.1c02212

19. Lewandowski G., Kujbid M., Wróblewska A., Epoxidation of 1,5,9-cyclododecatriene with hydrogen peroxide under phase-transfer catalysis conditions: Influence of selected parameters on the course of epoxidation, Reac Kinet Mech Cat., 2021, No. 132, pp. 983–1001, DOI: https://doi.org/10.1007/s11144-021-01960-7

20. Yarchak V.A., Kulikov L.A., Maksimov A.L., Karakhanov E.A., Epoxidation of olefins in the presence of molybdenum catalysts based on porous aromatic frameworks (In Russ.), Neftekhimiya = Petroleum Chemistry, 2023, V. 63, No. 1, pp. 100–109, DOI: https://doi.org/10.31857/S0028242123010094

21. Anozie U. C., Ju L. K., Microencapsulation of sulfur by calcium alginate, Journal of Applied Polymer Science, 2020, V. 137, No. 34, pp. 49005,

DOI: https://doi.org/10.1002/app.49005

22. Li J. et al., Preparation and application of poly (melamine-urea-formaldehyde) microcapsules filled with sulfur, Polymer-Plastics Technology and Engineering, 2011,

V. 50, No. 7, pp. 689–697, DOI: https://doi.org/10.1080/03602559.2010.551389

23. Zhang Z.S. et al., Preparation and morphological investigation of sulfur microcapsule produced in scale-up process via in situ polymerization, Advanced Materials Research, 2012, V. 479, pp. 636–639, DOI: https://doi.org/10.4028/www.scientific.net/AMR.479-481.636