Reactor for producing pharmaceutical particles in a precipitation process

Abstract

Reactors, reactor systems and methods for producing particles in a precipitation process are provided. The reactor includes a housing defining a reaction chamber, a stator assembly including two or more stators, a rotor assembly including two or more rotors, the rotor assembly configured for rotation about an axis of rotation relative to the stator assembly, a first inlet to supply a first reactant material to the reaction chamber at a first radial location, a second inlet to supply a second reactant material to the reaction chamber at a second radial location different from the first radial location, wherein the first and second reactant materials react to produce precipitation of particles in the reaction chamber, and an outlet to supply the particles formed in the reaction chamber.

1 . A reactor for producing particles in a precipitation process, comprising:
 a housing defining a reaction chamber;   a stator assembly including two or more stators in the reaction chamber;   a rotor assembly including two or more rotors in the reaction chamber, the rotor assembly configured for rotation about an axis of rotation relative to the stator assembly;   a first inlet to supply a first reactant material to the reaction chamber at a first radial location;   a second inlet to supply a second reactant material to the reaction chamber at a second radial location different from the first radial location, wherein the first and second reactant materials react to produce precipitation of particles in the reaction chamber; and   an outlet to supply the particles formed in the reaction chamber, wherein at least one stator of the two or more stators includes a plurality of circumferentially spaced teeth and wherein the second inlet includes openings located radially inwardly of and in radial alignment with respective teeth of said one stator.   
     
     
         2 . A reactor as defined in  claim 1 , wherein the stator assembly includes at least a first stator and a second stator, wherein the rotor assembly includes at least a first rotor, a second rotor and a third rotor, wherein the first inlet is positioned to supply the first reactant material to the reaction chamber upstream of the first rotor, and wherein the second inlet is positioned to supply the second reactant material to the reaction chamber in a region of the second stator. 
     
     
         3 . A reactor as defined in  claim 2 , wherein the stator assembly further includes a third stator and the rotor assembly further includes a fourth rotor, and wherein the third stator and the fourth rotor reduce the sizes of particles formed by reaction of the first and second reactant materials. 
     
     
         4 . A reactor as defined in  claim 1 , wherein the second inlet comprises a plurality of openings in communication with the reaction chamber, the openings spaced from an axis of the rotor assembly. 
     
     
         5 . A reactor as defined in  claim 1 , wherein the second inlet comprises four openings in said one stator, the four openings being equally spaced from an axis of rotation and spaced apart by 90° around said one stator. 
     
     
         6 . A reactor for producing particles in a precipitation process, comprising:
 a housing enclosing a reaction chamber;   a stator assembly including at least a first stator and a second stator in the reaction chamber;   a rotor assembly including at least a first rotor, second rotor and a third rotor in the reaction chamber;   a first inlet to supply a first reactant material to the reaction chamber upstream of the first rotor;   a second inlet to supply a second reactant material to the reaction chamber in a region of the second stator; and   an outlet to provide particles formed by reaction of the first and second reactant materials, wherein the first reactant material is increased in speed by the first rotor and is reduced to small droplets by the first stator and the second rotor, wherein the first reactant material reacts with the second reactant material downstream of the second inlet, wherein the second stator includes a plurality of circumferentially spaced teeth and wherein the second inlet includes openings located radially inwardly of and in radial alignment with respective teeth of the second stator.   
     
     
         7 . A reactor as defined in  claim 6 , wherein the stator assembly further includes a third stator and the rotor assembly further includes a fourth rotor, wherein the third stator and the fourth rotor reduce the sizes of particles formed by reaction of the first and second reactant materials. 
     
     
         8 . A reactor as defined in  claim 6 , wherein the rotors and the stators are concentric with respect to an axis of rotation of the rotor assembly. 
     
     
         9 . A reactor as defined in  claim 6 , wherein the first inlet is located on an axis of rotation of the rotor assembly. 
     
     
         10 . A reactor as defined in  claim 6 , wherein the second inlet comprises a plurality of openings in communication with the reaction chamber, the openings spaced from an axis of rotation of the rotor assembly. 
     
     
         11 . A reactor as defined in  claim 6 , wherein the second inlet comprises several openings in communication with the reaction chamber, the openings equally spaced from an axis of rotation of the rotor assembly and equally spaced around the axis of rotation. 
     
     
         12 . A reactor as defined in  claim 6 , wherein the second inlet comprises four openings in the second stator, the four openings being equally spaced from an axis of rotation and spaced apart by 90° around the second stator. 
     
     
         13 . A reactor as defined in  claim 6 , wherein particles are produced continuously by the precipitation process in the reaction chamber. 
     
     
         14 . A reactor system for producing particles in a precipitation process, comprising:
 a reactor including a housing enclosing a reaction chamber, a stator assembly including at least a first stator and a second stator in the reaction chamber, a rotor assembly including at least a first rotor, a second rotor and a third rotor in the reaction chamber, a first inlet coupled to the reaction chamber upstream of the first rotor, a second inlet coupled to the reaction chamber in a region of the second stator, and an outlet of the reaction chamber;   a drive mechanism configured to rotate the rotor assembly relative to the stator assembly in the reaction chamber;   a first source configured to supply a first reactant material to the first inlet of the reactor; and   a second source configured to supply a second reactant material to the second inlet of the reactor, wherein the first reactant material is increased in speed by the first rotor and is reduced to small droplets by the first stator and the second rotor, wherein the first reactant material reacts with the second reactant material downstream of the second inlet to provide, at the outlet of the reaction chamber, particles formed by reaction of the first and second reactant materials, wherein the second stator includes a plurality of circumferentially spaced teeth and wherein the second inlet includes openings located radially inwardly of and in radial alignment with respective teeth of the second stator.   
     
     
         15 . A reactor system as defined in  claim 14 , wherein the first source includes a first process hold vessel coupled through a first pump to the first inlet of the reactor. 
     
     
         16 . A reactor system as defined in  claim 15 , wherein the second source includes a second process hold vessel coupled through a second pump to the second inlet of the reactor. 
     
     
         17 . A method for producing particles in a precipitation process, comprising:
 providing a reactor having a reaction chamber and including a stator assembly including at least a first stator and a second stator in the reaction chamber and a rotor assembly including at least a first rotor, a second rotor and a third rotor in the reaction chamber;   rotating the rotor assembly relative to the stator assembly in the reaction chamber;   supplying a first reactant material to the reaction chamber upstream of the first rotor; and   supplying a second reactant material to the reaction chamber in a region of the second stator, wherein the first reactant material is increased in speed by the first rotor and is reduced to small droplets by the first stator and the second rotor, wherein the first reactant material reacts with the second reactant material downstream of the second inlet to provide at an outlet of the reaction chamber particles formed by reaction of the first and second reactant materials.   
     
     
         18 . A method as defined in  claim 17 , wherein supplying a first reactant material comprises supplying acetic acid solution to a first inlet of the reaction chamber. 
     
     
         19 . A method as defined in  claim 18 , wherein supplying a second reactant material comprises supplying an FDKP solution to a second inlet of the reaction chamber. 
     
     
         20 . A method as defined in  claim 17 , wherein the second reactant material is supplied to the reaction chamber through a plurality of openings in the second stator. 
     
     
         21 . A method as defined in  claim 17 , wherein the second stator includes a plurality of teeth in a circular pattern and wherein the second reactant material is supplied to the reaction chamber through the second stator inwardly of the teeth. 
     
     
         22 . A method as defined in  claim 17 , wherein the second stator includes a circular ring having a plurality of radial openings and wherein the second reactant material is supplied to the reaction chamber through the second stator inwardly of the circular ring. 
     
     
         23 . A method for producing particles in a precipitation process, comprising:
 providing a reactor having a reaction chamber and including a stator assembly having two or more stators and a rotor assembly having two or more rotors;   rotating the rotor assembly about an axis of rotation relative to the stator assembly;   supplying a first reactant material to the reaction chamber at a first radial location; and   supplying a second reactant material to the reaction chamber at a second radial location different from the first radial location, wherein the first and second reactant materials react to produce precipitation of particles in the reaction chamber.   
     
     
         24 . A reactor for producing particles in a precipitation process, comprising:
 a housing enclosing a reaction chamber;   a stator assembly including at least a first stator and a second stator in the reaction chamber;   a rotor assembly including at least a first rotor, second rotor and a third rotor in the reaction chamber;   a first inlet to supply a first reactant material to the reaction chamber upstream of the first rotor;   a second inlet to supply a second reactant material to the reaction chamber in a region of the second stator; and   an outlet to provide particles formed by reaction of the first and second reactant materials, wherein the first reactant material is increased in speed by the first rotor and is reduced to small droplets by the first stator and the second rotor, wherein the first reactant material reacts with the second reactant material downstream of the second inlet, wherein the first stator and the second stator each include a circular ring having a plurality of radial openings and wherein the second inlet includes openings located radially inwardly of the circular ring of the second stator.