Solvent-activated reactor

Abstract

A reactor for an in-situ production of a chemical product in high yield are presented. The reactor, which may be placed in a main solvent, includes a core and a reactor wall around the core. The reactor wall allows controlled permeation of the main solvent to the core. The core contains a reactant that reacts to produce a target product upon being contacted by a main solvent. The target product leaves the reactor at a controlled rate. Because the amount of the main solvent that permeates into the reactor is controlled, a high concentration of the reactant is maintained inside the reactor, resulting in a higher yield of the desired chemical product than if the reactants were directly added to the body of main solvent.

1 . A reactor that generates a target product when placed in contact with a main solvent, the reactor comprising: 
 a reactor wall forming a reactor space, the reactor wall allowing a controlled permeation of the main solvent into the reactor space; and    a core in the reactor space, wherein the core includes a reactant that, upon contacting the main solvent, starts a chemical reaction in the reactor space to generate the target product, and wherein the reactor wall allows the target product to leave the reactor space at a predetermined rate.    
   
   
       2 . The reactor of  claim 1 , wherein the reactor wall disintegrates when the concentration of the target product in the main solvent outside of the reactor is equal to or greater than a predetermined level.  
   
   
       3 . The reactor of  claim 1 , wherein the reactor wall disintegrates when the generated amount of the target product is equal to or greater than the critical level.  
   
   
       4 . The reactor of  claim 1 , wherein the reactor wall contains a silicate-based material.  
   
   
       5 . The reactor of  claim 1 , wherein the reactor wall contains a polymer and a surfactant.  
   
   
       6 . The reactor of  claim 1 , wherein the reactor wall is a porous membrane.  
   
   
       7 . The reactor of  claim 1 , wherein the reactor wall is a first reactor and the reactor space is a first reactor space, further comprising a second reactor wall formed around the core to form a second reactor space.  
   
   
       8 . The reactor of  claim 1 , wherein the target product is dioxirane, the core comprising: 
 about 10-80 wt. % an oxidant;    about 0.5-20 wt. % a carbonyl donor;    about 0-50 wt. % a binder;    about 0-50 wt. % a filler; and    about 0-30 wt. % a pH buffer, wherein the core is > about 50 wt. % solids.    
   
   
       9 . The reactor of  claim 8 , wherein the reactor wall comprises a coating material that allows a polar solvent to permeate into the reactor space while restricting diffusion of the reactant and the target product out of the reactor space, the coating material having a lower solubility in the main solvent than the oxidant and the target product.  
   
   
       10 . The reactor of  claim 9 , wherein the core is a homogeneous agglomeration of components.  
   
   
       11 . The reactor of  claim 9 , wherein the coating material is a silicate-based material.  
   
   
       12 . The reactor of  claim 9 , wherein the coating material comprises one or both of a polymer and a surfactant.  
   
   
       13 . The reactor of  claim 9 , wherein the reactor wall is a porous membrane.  
   
   
       14 . The reactor of  claim 9  further comprising a soluble layer formed around the core, wherein the soluble layer contains at least one of a silicate, a cellulose, chitin, chitosan, polymaleic acid, polyacrylic acid, polyacrylamides, polyvinylalcohols, polyethylene glycols, their respective surrogates.  
   
   
       15 . The reactor of  claim 14 , wherein the soluble layer is formed between the core and the reactor wall.  
   
   
       16 . The reactor of  claim 14 , wherein the soluble layer is formed around the reactor wall.  
   
   
       17 . The reactor of  claim 9 , wherein the reactor space is a first reactor space and the reactor wall is a first wall, further comprising a second wall formed around the core to form the second reactor space having a pH level that is different from a pH level of the first reactor space.  
   
   
       18 . The reactor of  claim 17 , wherein the second reactor is one of a silicate based material, a combination of a polymer and a surfactant, or a porous membrane.  
   
   
       19 . The reactor of  claim 17 , wherein the chemical reaction is a first chemical reaction, and wherein a second chemical reaction occurs in the second reactor space to produce the target product.  
   
   
       20 . The reactor of  claim 17 , wherein the second wall is formed around the first wall.  
   
   
       21 . The reactor of  claim 17 , wherein the second wall is formed between the core and the first wall.  
   
   
       22 . The reactor of  claim 17  further comprising a layer positioned between the first wall and the second wall, the layer containing one or more of a pH buffer, a stabilizer, and a reactant.  
   
   
       23 . The reactor of  claim 9 , wherein the reactor wall comprises a combination of a polymer and an alloying compound.  
   
   
       24 . The reactor of  claim 8 , wherein the core is shaped into a particle, granule, nugget, wafer, disc, briquette, and puck.  
   
   
       25 . The reactor of  claim 8 , wherein the reactant is at least one of potassium persulfate, sodium persulfate, ammonium persulfate, potassium monopersulfate, permanganate, and a Caro's acid precursor.  
   
   
       26 . The method of  claim 25 , wherein the Caro's acid precursor is a combination of a peroxide donor and a sulfuric acid donor.  
   
   
       27 . The method of  claim 26 , wherein the peroxide donor is one of urea peroxide, calcium peroxide, magnesium peroxide, sodium peroxide, potassium peroxide, perborate, perphosphate, persilicate, and percarbonate, and wherein the sulfuric acid donor is one of sodium bisulfate and pyrosulfate.  
   
   
       28 . The method of  claim 8 , wherein the carbonyl donor has 3-20 carbons and at least one carbonyl group.  
   
   
       29 . The reactor of  claim 1 , wherein the target product is percarboxylic acid, the core comprising: 
 about 10-80 wt. % an oxidant;    about 1-40 wt. % a carboxyl group donor;    about 0-50 wt. % a binder;    about 0-50 wt. % a filler; and    about 0-30 wt. % a pH buffer, wherein the core is > about 50 wt. % solids.    
   
   
       30 . The reactor of  claim 29 , wherein the reactor wall comprises a coating material that allows a polar solvent to permeate into the reactor space while restricting diffusion of the reactant and the target product out of the reactor space, the coating material having a lower solubility in the main solvent than the oxidant and the target product.  
   
   
       31 . The reactor of  claim 29 , wherein the core is a homogeneous agglomeration of components.  
   
   
       32 . The reactor of  claim 29 , wherein the reactor wall comprises a silicate-based material.  
   
   
       33 . The reactor of  claim 29 , wherein the reactor wall comprises one or both of a polymer and a surfactant.  
   
   
       34 . The reactor of  claim 29 , wherein the reactor wall is a porous membrane.  
   
   
       35 . The reactor of  claim 29  further comprising a soluble layer formed around the core, wherein the soluble layer contains at least one of a silicate, a cellulose, chitin, chitosan, polymaleic acid, polyacrylic acid, polyacrylamides, polyvinylalcohols, polyethylene glycols, their respective surrogates  
   
   
       36 . The reactor of  claim 35 , wherein the soluble layer is formed between the core and the reactor wall.  
   
   
       37 . The reactor of  claim 35 , wherein the soluble layer is formed around the reactor wall.  
   
   
       38 . The reactor of  claim 29 , wherein the reactor space is a first reactor space and the reactor wall is a first wall, further comprising a second wall formed around the core to form the second reactor space having a pH level that is different from a pH level of the first reactor space.  
   
   
       39 . The reactor of  claim 38 , wherein the second reactor is one of a silicate based material, a combination of a polymer and a surfactant, or a porous membrane.  
   
   
       40 . The reactor of  claim 38 , wherein the chemical reaction is a first chemical reaction, and wherein a second chemical reaction occurs in the second reactor space to produce the target product.  
   
   
       41 . The reactor of  claim 38 , wherein the second wall is formed around the first wall.  
   
   
       42 . The reactor of  claim 38 , wherein the second wall is formed between the core and the first wall.  
   
   
       43 . The reactor of  claim 38  further comprising a layer positioned between the first wall and the second wall, the layer containing one or more of a pH buffer, a stabilizer, and a reactant.  
   
   
       44 . The reactor of  claim 29 , wherein the reactor wall comprises a combination of a polymer and an alloying compound.  
   
   
       45 . The reactor of  claim 29 , wherein the core is one of a particle, granule, nugget, wafer, disc, briquette, and puck.  
   
   
       46 . The reactor of  claim 29 , wherein the reactant is one of urea peroxide, calcium peroxide, magnesium peroxide, sodium percarbonate sodium perborate, persulfate(s), monopersulfate, persilicate, perphosphate, sodium peroxide, lithium peroxide, potassium peroxide, and permanganate.  
   
   
       47 . The reactor of  claim 29 , wherein the reactant is a first reactant, and wherein the carboxyl group donor is a second reactant having 1-20 carbons and a carboxylic acid functional group.  
   
   
       48 . The reactor of  claim 29 , wherein the pH buffer is an organic acid having 1-10 carbons and a carboxyl functional group.  
   
   
       49 . The reactor of  claim 29 , wherein the pH buffer is an inorganic acid.  
   
   
       50 . The reactor of  claim 1 , wherein the target product is a hypohalite, the core comprising: 
 about 10-80 wt. % an oxidant;    about 0.5-20 wt. % a halogen donor;    about 0-50 wt. % a binder;    about 0-50 wt. % a filler; and    about 0-30 wt. % a pH buffer, wherein the core is > about 50 wt. % solids.    
   
   
       51 . The reactor of  claim 50 , wherein the reactor wall comprises a coating material that allows a polar solvent to permeate into the reactor space while restricting diffusion of the reactant and the target product out of the reactor space, the coating material having a lower solubility in the main solvent than the oxidant and the target product.  
   
   
       52 . The reactor of  claim 50 , wherein the core is a homogeneous agglomeration of components.  
   
   
       53 . The reactor of  claim 50 , wherein the reactor wall comprises a silicate-based material.  
   
   
       54 . The reactor of  claim 50 , wherein the reactor wall comprises one or both of a polymer and a surfactant.  
   
   
       55 . The reactor of  claim 50 , wherein the reactor wall is a porous membrane.  
   
   
       56 . The reactor of  claim 50  further comprising a soluble layer formed around the core, wherein the soluble layer contains at least one of a silicate, a cellulose, chitin, chitosan, polymaleic acid, polyacrylic acid, polyacrylamides, polyvinylalcohols, polyethylene glycols, their respective surrogates.  
   
   
       57 . The reactor of  claim 56 , wherein the soluble layer is formed between the core and the reactor wall.  
   
   
       58 . The reactor of  claim 56 , wherein the layer is formed around the reactor wall.  
   
   
       59 . The reactor of  claim 50 , wherein the reactor wall is a first wall, further comprising a second wall formed around the core to provide support for the reactor wall.  
   
   
       60 . The reactor of  claim 59 , wherein the second reactor is one of a silicate based material, a combination of a polymer and a surfactant, or a porous membrane.  
   
   
       61 . The reactor of  claim 59 , wherein the second wall is formed around the first wall.  
   
   
       62 . The reactor of  claim 59 , wherein the second wall is formed between the core and the first wall.  
   
   
       63 . The reactor of  claim 59  further comprising a layer positioned between the first wall and the second wall, the layer containing one or more of a pH buffer, a stabilizer, and a reactant.  
   
   
       64 . The reactor of  claim 50 , wherein the reactor wall comprises a combination of a polymer and an alloying compound.  
   
   
       65 . The reactor of  claim 50 , wherein the core is one of a particle, granule, nugget, wafer, disc, briquette, and puck.  
   
   
       66 . The reactor of  claim 50 , wherein the reactant is at least one of potassium persulfate, sodium persulfate, ammonium persulfate, potassium monopersulfate, permanganate, and a Caro's acid precursor.  
   
   
       67 . The method of  claim 66 , wherein the Caro's acid precursor is a combination of a peroxide donor and a sulfuric acid donor.  
   
   
       68 . The method of  claim 67 , wherein the peroxide donor is one of urea peroxide, calcium peroxide, magnesium peroxide, sodium peroxide, potassium peroxide, perborate, perphosphate, persilicate, and percarbonate, and wherein the sulfuric acid donor is one of sodium bisulfate and pyrosulfate.  
   
   
       69 . The reactor of  claim 1 , wherein the target product is an N-halo-amine, the core comprising: 
 about 10-80 wt. % an oxidant;    about 0.5-20 wt. % a halogen donor;    about 2-50 wt. % stabilizer;    about 0-50 wt. % a binder;    about 0-50 wt. % a filler; and    about 0-30 wt. % a pH buffer, wherein the core is > about 50 wt. % solids.    
   
   
       70 . The reactor of  claim 69 , wherein the reactor wall comprises a coating material that allows a polar solvent to permeate into the reactor space while restricting diffusion of the reactant and the target product out of the reactor space, the coating material having a lower solubility in the main solvent than the oxidant and the target product.  
   
   
       71 . The reactor of  claim 69 , wherein the core is a homogeneous agglomeration of components.  
   
   
       72 . The reactor of  claim 69 , wherein the reactor wall comprises a silicate-based material.  
   
   
       73 . The reactor of  claim 69 , wherein the reactor wall comprises one or both of a polymer and a surfactant.  
   
   
       74 . The reactor of  claim 69 , wherein the reactor wall is a porous membrane.  
   
   
       75 . The reactor of  claim 69  further comprising a soluble layer formed around the core, wherein the soluble layer contains at least one of a silicate, a cellulose, chitin, chitosan, polymaleic acid, polyacrylic acid, polyacrylamides, polyvinylalcohols, polyethylene glycols, their respective surrogates.  
   
   
       76 . The reactor of  claim 75 , wherein the layer is formed between the core and the reactor wall.  
   
   
       77 . The reactor of  claim 75 , wherein the layer is formed around the reactor wall.  
   
   
       78 . The reactor of  claim 69 , wherein the reactor space is a first reactor space and the reactor wall is a first wall, further comprising a second wall formed around the core to form the second reactor space having a pH level that is different from a pH level of the first reactor space.  
   
   
       79 . The reactor of  claim 78 , wherein the second reactor is one of a silicate based material, a combination of a polymer and a surfactant, or a porous membrane.  
   
   
       80 . The reactor of  claim 78 , wherein the chemical reaction is a first chemical reaction, and wherein a second chemical reaction occurs in the second reactor space to produce the target product.  
   
   
       81 . The reactor of  claim 78 , wherein the second wall is formed around the first wall.  
   
   
       82 . The reactor of  claim 78 , wherein the second wall is formed between the core and the first wall.  
   
   
       83 . The reactor of  claim 78  further comprising a layer positioned between the first wall and the second wall, the layer containing one or more of a pH buffer, a stabilizer, and a reactant.  
   
   
       84 . The reactor of  claim 69 , wherein the reactor wall comprises a combination of a polymer and an alloying compound.  
   
   
       85 . The reactor of  claim 69 , wherein the core is one of a particle, granule, nugget, wafer, disc, briquette, and puck.  
   
   
       86 . The reactor of  claim 69 , wherein the reactant is one of potassium persulfate, sodium persulfate, ammonium persulfate, potassium monopersulfate, permanganate and Caro's acid precursors.  
   
   
       87 . The reactor of  claim 86 , wherein the reactant is a first reactant, the core further comprising a second reactant that is one of a monovalent metal salt, a divalent metal salt, and a trivalent metal salt.  
   
   
       88 . The reactor of  claim 86 , wherein the core further comprises an N-hydrogen donor capable of reacting with hypo-halite to generate the target product.  
   
   
       89 . The reactor of  claim 69 , wherein the core further comprises a chlorate donor.  
   
   
       90 . The reactor of  claim 69 , wherein the pH buffer is an organic acid having 1-10 carbons and a carboxyl functional group.  
   
   
       91 . The reactor of  claim 69 , wherein the pH buffer is an inorganic acid.  
   
   
       92 . The reactor of  claim 1 , wherein the target product chlorine dioxide, the core comprising: 
 about 10-80 wt. % an oxidant;    about 0.5-20 wt. % a halogen donor;    about 0.5-15 wt. % chlorite donor;    about 0-50 wt. % a binder;    about 0-50 wt. % a filler; and    about 0-30 wt. % a pH buffer, wherein the core is > about 50 wt. % solids.    
   
   
       93 . The reactor of  claim 92 , wherein the reactor wall comprises a coating material that allows a polar solvent to permeate into the reactor space while restricting diffusion of the reactant and the target product out of the reactor space, the coating material having a lower solubility in the main solvent than the oxidant and the target product.  
   
   
       94 . The reactor of  claim 92 , wherein the core is a homogeneous agglomeration of components.  
   
   
       95 . The reactor of  claim 92 , wherein the reactor wall comprises a silicate-based material.  
   
   
       96 . The reactor of  claim 92 , wherein the reactor wall comprises one or both of a polymer and a surfactant.  
   
   
       97 . The reactor of  claim 92 , wherein the reactor wall is a porous membrane.  
   
   
       98 . The reactor of  claim 92  further comprising a soluble layer formed around the core, wherein the soluble layer contains at least one of a silicate, a cellulose, chitin, chitosan, polymaleic acid, polyacrylic acid, polyacrylamides, polyvinylalcohols, polyethylene glycols, their respective surrogates.  
   
   
       99 . The reactor of  claim 92 , wherein the soluble layer is formed between the core and the reactor wall.  
   
   
       100 . The reactor of  claim 92 , wherein the soluble layer is formed around the reactor wall.  
   
   
       101 . The reactor of  claim 92 , wherein the reactor space is a first reactor space and the reactor wall is a first wall, further comprising a second wall formed around the core to form the second reactor space having a pH level that is different from a pH level of the first reactor space.  
   
   
       102 . The reactor of  claim 101 , wherein the second reactor is one of a silicate based material, a combination of a polymer and a surfactant, or a porous membrane.  
   
   
       103 . The reactor of  claim 101 , wherein the chemical reaction is a first chemical reaction, and wherein a second chemical reaction occurs in the second reactor space to produce the target product.  
   
   
       104 . The reactor of  claim 101 , wherein the second wall is formed around the first wall.  
   
   
       105 . The reactor of  claim 101 , wherein the second wall is formed between the core and the first wall.  
   
   
       106 . The reactor of  claim 101  further comprising a layer positioned between the first wall and the second wall, the layer containing one or more of a pH buffer, a stabilizer, and a reactant.  
   
   
       107 . The reactor of  claim 92 , wherein the reactor wall comprises a combination of a polymer and an alloying compound.  
   
   
       108 . The reactor of  claim 92 , wherein the core is one of a particle, granule, nugget, wafer, disc, briquette, and puck.  
   
   
       109 . The reactor of  claim 92 , wherein the reactant is one of potassium, sodium, ammonium persulfate, potassium monopersulfate, permanganate and a Caro's acid precursor.  
   
   
       110 . The reactor of  claim 109 , wherein the halogen donor is a mono-valent or di-valent metal salt.  
   
   
       111 . The reactor of  claim 109 , wherein the core further comprises a chlorate donor.  
   
   
       112 . The reactor of  claim 92 , wherein the pH buffer comprises an organic acid having 1-10 carbons and a carboxyl functionality.  
   
   
       113 . The reactor of  claim 92 , wherein the pH buffer comprises an inorganic acid.  
   
   
       114 . The reactor of  claim 92 , wherein the reactant is one of urea peroxide, calcium peroxide, magnesium peroxide, sodium percarbonate sodium perborate, persulfate(s), monopersulfate, persilicate, perphosphate, sodium, lithium, potassium peroxide.  
   
   
       115 . The reactor of  claim 114 , wherein the core further comprises a chlorate donor.  
   
   
       116 . The reactor of  claim 1 , wherein the target product is a hydroxyl radical, the core comprising: 
 about 10-80 wt. % an oxidant;    about 0.001-10 wt. % a transition metal;    about 0-50 wt. % a binder;    about 0-50 wt. % a filler; and    about 1-30 wt. % a pH buffer, wherein the core is > about 50 wt. % solids.    
   
   
       117 . The reactor of  claim 116 , wherein the reactor wall comprises a coating material that allows a polar solvent to permeate into the reactor space while restricting diffusion of the reactant and the target product out of the reactor space, the coating material having a lower solubility in the main solvent than the oxidant and the target product.  
   
   
       118 . The reactor of  claim 116 , wherein the core is a homogeneous agglomeration of components.  
   
   
       119 . The reactor of  claim 116 , wherein the reactor wall comprises a silicate-based material.  
   
   
       120 . The reactor of  claim 116 , wherein the reactor wall comprises one or both of a polymer and a surfactant.  
   
   
       121 . The reactor of  claim 116 , wherein the reactor wall is a porous membrane.  
   
   
       122 . The reactor of  claim 116  further comprising a soluble layer formed around the core, wherein the soluble layer contains at least one of a silicate, a cellulose, chitin, chitosan, polymaleic acid, polyacrylic acid, polyacrylamides, polyvinylalcohols, polyethylene glycols, their respective surrogates.  
   
   
       123 . The reactor of  claim 122 , wherein the soluble layer is formed between the core and the reactor wall.  
   
   
       124 . The reactor of  claim 122 , wherein the soluble layer is formed aounrd the reactor wall.  
   
   
       125 . The reactor of  claim 116 , wherein the reactor space is a first reactor space and the reactor wall is a first wall, further comprising a second wall formed around the core to form the second reactor space having a pH level that is different from a pH level of the first reactor space.  
   
   
       126 . The reactor of  claim 116 , wherein the second reactor is one of a silicate based material, a combination of a polymer and a surfactant, or a porous membrane.  
   
   
       127 . The reactor of  claim 126 , wherein the chemical reaction is a first chemical reaction, and wherein a second chemical reaction occurs in the second reactor space to produce the target product.  
   
   
       128 . The reactor of  claim 126 , wherein the second wall is formed around the first wall.  
   
   
       129 . The reactor of  claim 126 , wherein the second wall is formed between the core and the first wall.  
   
   
       130 . The reactor of  claim 125  further comprising a layer positioned between the first wall and the second wall, the layer containing one or more of a pH buffer, a stabilizer, and a reactant.  
   
   
       131 . The reactor of  claim 116 , wherein the reactor wall comprises a combination of a polymer and an alloying compound.  
   
   
       132 . The reactor of  claim 116 , wherein the core is one of a particle, granule, nugget, wafer, disc, briquette, and puck.  
   
   
       133 . The reactor of  claim 116 , wherein the reactant is one of urea peroxide, calcium peroxide, magnesium peroxide, sodium percarbonate sodium perborate, persulfate(s), monopersulfate, persilicate, perphosphate, sodium, lithium, permanganate, and potassium peroxide.  
   
   
       134 . The reactor of  claim 116 , wherein the transition metal is a chelating agent selected from a group consisting of trisodium pyrophosphate, tetrasodium diphosphate, sodium hexametaphosphate, sodium trimetaphosphate, sodium tripolyphosphate, potassium tripolyphosphate, phosphonic acid, di-phosphonic acid compound, tri-phosphonic acid compound, a salt of a phosphonic acid compound, ethylene diamine-tetra-acetic acid, gluconate, or other ligand forming compound.  
   
   
       135 . The reactor of  claim 116 , wherein the pH buffer is an organic acid having 1-10 carbons and at least one carboxyl functional group.  
   
   
       136 . The reactor of  claim 116 , wherein the pH buffer is an inorganic acid.  
   
   
       137 . The reactor of  claim 116  further comprising a metal catalyst in the core.  
   
   
       138 . The reactor of  claim 137 , wherein the metal catalyst is selected from a group consisting of: Cu (II), Mn (II), Co (II), Fe (II), Fe (III), Ni (II), Ti (IV), Mo (V), Mo (VI), W (VI), Ru (III), and Ru (IV).  
   
   
       139 . The reactor of  claim 137 , wherein the metal catalyst is coated on the core.  
   
   
       140 . The reactor of  claim 137  further comprising a non-solvent component in the reactor wall, wherein the metal catalyst is combined with the non-solvent component of the membrane coating, whereby removal of the volatile non-solvent component results in formation of channels and pores that are lined with the metal catalyst.  
   
   
       141 . A method of making a reactor that generates a target product when placed in contact with a main solvent, the method comprising: 
 preparing a core containing a reactant that, upon contacting the main solvent, generates the target product through a chemical reaction; and    forming a reactor wall around a reactor space such that the reactor space contains the core, the reactor wall allowing a controlled permeation of the main solvent into the reactor space wherein the chemical reaction occurs in the reactor space, and wherein the target product leaves the reactor space at a predetermined rate.    
   
   
       142 . The method of  claim 141  further comprising forming the reactor wall such that the reactor wall disintegrates when the concentration of the target product in the main solvent outside of the reactor is equal to or greater than a predetermined level.  
   
   
       143 . The method of  claim 141  further comprising forming the reactor wall such that the reactor wall disintegrates when the concentration of the target product is equal to or greater than the critical level.  
   
   
       144 . The method of  claim 141 , wherein the reactant is an oxidizer.  
   
   
       145 . The method of  claim 141 , wherein preparing the core comprises mixing and agglomerating core components.  
   
   
       146 . The method of  claim 145  further comprising adding a binder to the core.  
   
   
       147 . The method of  claim 145  further comprising drying the agglomerated core components simultaneously with the forming of the reactor wall.  
   
   
       148 . The method of  claim 145  further comprising drying the agglomerated core components before the forming of the reactor wall.  
   
   
       149 . The method of  claim 141 , wherein forming the reactor wall comprises applying a coating material in the form of a liquid, gel, suspension, or foam.  
   
   
       150 . The method of  claim 141 , wherein forming the reactor wall comprises: 
 dissolving a silicate-based material in a silicate solvent to form a silicate solution; and    applying the silicate solution to the core.    
   
   
       151 . The method of  claim 141 , wherein forming the reactor wall comprises: 
 combining a hydrophobic polymer, a hydrophilic component, and an amphipathic component to form an emulsion; and    coating the core with the emulsion.    
   
   
       152 . The method of  claim 151  further comprising removing the hydrophilic component to form pores in the reactor wall.  
   
   
       153 . The method of  claim 141 , wherein forming the reactor wall comprises forming a porous membrane.  
   
   
       154 . The method of  claim 153 , wherein the porous membrane comprises a polymer, a solvent, and a non-solvent.  
   
   
       155 . The method of  claim 154 , wherein polymer is hydrophobic, further comprising: 
 forming a mixture of the polymer and the solvent;    coating the core with the mixture to form a mixture layer; and    applying the non-solvent on the mixture layer.    
   
   
       156 . The method of  claim 154 , wherein the forming of the porous membrane comprises: 
 dissolving the polymer in the solvent to form a polymer solution;    adding the non-solvent to the polymer solution to form a polymer mixture; and    coating the core with the polymer mixture.    
   
   
       157 . The method of  claim 156 , wherein the non-solvent is soluble in the solvent, further comprising adjusting a porosity of the membrane by varying an amount of the non-solvent.  
   
   
       158 . The method of  claim 154  further comprising removing portions of the solvent and non-solvent.  
   
   
       159 . The method of  claim 158  further comprising combining the non-solvent with a metal catalyst so that the metal catalyst remains on the reactor wall after the removing of the non-solvent.  
   
   
       160 . The method of  claim 158 , wherein the removing comprises evaporating.  
   
   
       161 . The method of  claim 154  further comprising combining the polymer with an additive, wherein the additive is one of an alloying agent, a cross-linking agent, and a plasticizer.  
   
   
       162 . The method of  claim 154 , wherein the reactor wall comprises a hydrophobic polymer precursor, a cross-linking agent, a solvent, and a non-solvent, and wherein the forming of the reactor wall comprises: 
 applying a coating material on the core to form a film;    coating the film with an effective amount of oxidizer to induce polymerization between the polymer precursor and the cross-linking agent to form the reactor wall;    forming pores in the reactor wall by removing the solvent and the non-solvent.    
   
   
       163 . The method of  claim 141  further comprising forming a soluble layer around the core, wherein the soluble layer contains at least one of a silicate, a cellulose, chitin, chitosan, polymaleic acid, polyacrylic acid, polyacrylamides, polyvinylalcohols, polyethylene glycols, their respective surrogates.  
   
   
       164 . The method of  claim 163  further comprising forming the soluble layer between the reactor wall and the core.  
   
   
       165 . The method of  claim 163  further comprising forming the soluble layer around the reactor wall.  
   
   
       166 . The method of  claim 141 , wherein the reactor wall is a first reactor wall, further comprising forming a second reactor wall that supports the first reactor wall.  
   
   
       167 . The method of  claim 166  further comprising forming an intermediate layer between the first reactor wall and the second reactor wall, wherein the intermediate layer contains one or more of a pH buffer, a stabilizer, or a reactant for the chemical reaction.  
   
   
       168 . The method of  claim 141 , wherein the target product is dioxirane, and wherein preparing the core comprises: 
 combining an oxidant in an amount of about 10-80 wt. % of the core, one or more carbonyl donors in an amount of about 0.5-20 wt. % of the core, a binder in an amount of about 0-50 wt. % of the core, a filler in an amount of about 0-50 wt. % of the core, and a pH buffering agent in an amount of about 0-30 wt. % of the core such that at least about 50 wt. % of the core is solids.    
   
   
       169 . The method of  claim 168 , wherein preparing the core comprises mixing core components to produce an agglomerate.  
   
   
       170 . The method of  claim 168  further comprising: 
 drying the core; and    coating the core with one of: a silicate-based material, a mixture of a polymer and a surfactant, and a porous membrane.    
   
   
       171 . The method of  claim 168 , wherein the reactor wall, upon contact with a polar solvent, allows the solvent to permeate into the reactor space while restricting a diffusion of the reactant and the target product out of the reactor.  
   
   
       172 . The method of  claim 168 , wherein a solubility of the reactor wall in the main solvent is lower than a solubility of the oxidant and the solubility of the target product in the main solvent.  
   
   
       173 . The method of  claim 168 , wherein the reactant is at least one of potassium persulfate, sodium persulfate, ammonium persulfate, potassium monopersulfate, permanganate, and a Caro's acid precursor.  
   
   
       174 . The method of  claim 173 , wherein the Caro's acid precursor is one of a peroxide donor and a sulfuric acid donor.  
   
   
       175 . The method of  claim 174 , wherein the peroxide donor is one of urea peroxide, calcium peroxide, magnesium peroxide, sodium peroxide, potassium peroxide, perborate, perphosphate, persilicate, and percarbonate, and wherein the sulfuric acid donor is one of sodium bisulfate and pyrosulfate.  
   
   
       176 . The method of  claim 173 , wherein the reactant is an oxidizer reactant, the core further comprising an oxidizable reactant having 3-20 carbons and at least one carbonyl group.  
   
   
       177 . The method of  claim 141 , wherein the target product is percarboxylic acid, and wherein preparing the core comprises: 
 combining an oxidant in an amount of about 10-80 wt. % of the core, one or more carboxyl group donors in an amount of about 1-40 wt. % of the core, a binder in an amount of about 0-50 wt. % of the core, a filler in an amount of about 0-50 wt. % of the core, and a pH buffering agent in an amount of about 0-30 wt. % of the core, such that at least about 50 wt. % of the core is solids.    
   
   
       178 . The method of  claim 177 , wherein preparing the core comprises mixing core components to produce an agglomerate.  
   
   
       179 . The method of  claim 177  further comprising: 
 drying the core; and    coating the core with one of: a silicate-based material, a mixture of a polymer and a surfactant, and a porous membrane.    
   
   
       180 . The method of  claim 177 , wherein the reactor wall, upon contact with a polar solvent, allows the solvent to permeate into the reactor space while restricting a diffusion of the reactant and the target product out of the reactor.  
   
   
       181 . The method of  claim 177 , wherein a solubility of the reactor wall in the main solvent is lower than a solubility of the oxidant and the solubility of the target product in the main solvent.  
   
   
       182 . The method of  claim 177 , wherein the reactant is one of urea peroxide, calcium peroxide, magnesium peroxide, sodium percarbonate sodium perborate, persulfate(s), monopersulfate, persilicate, perphosphate, sodium peroxide, lithium peroxide, permanganate, and potassium peroxide.  
   
   
       183 . The method of  claim 177 , wherein the reactant is a first reactant, the one or more of the carboxyl group donors include a second reactant having 1-20 carbons and a carboxylic acid functional group.  
   
   
       184 . The method of  claim 141 , wherein the target product is hypohalite and wherein preparing the core comprises: 
 combining an oxidant in an amount of about 10-80 wt. % of the core, a halogen donor in an amount of about 0.5-20 wt. % of the core, a binder in an amount of about 0-50 wt. % of the core, a filler in an amount of about 0-50 wt. % of the core, and a pH buffering agent in an amount of about 0-30 wt. % of the core such that at least about 50 wt. % of the core is solids.    
   
   
       185 . The method of  claim 184 , wherein preparing the core comprises mixing core components to produce an agglomerate.  
   
   
       186 . The method of  claim 184  further comprising applying a film around the core, wherein the film contains at least one of a silicate, a cellulose, chitin, chitosan, polymaleic acid, polyacrylic acid, polyacrylamides, polyvinylalcohols, polyethylene glycols, their respective surrogates.  
   
   
       187 . The method of  claim 184 , wherein the reactor wall, upon contact with a polar solvent, allows the solvent to permeate into the reactor space while restricting a diffusion of the reactant and the target product out of the reactor.  
   
   
       188 . The method of  claim 184 , wherein a solubility of the reactor wall in the main solvent is lower than a solubility of the oxidant and the solubility of the target product in the main solvent.  
   
   
       189 . The method of  claim 184 , wherein forming the reactor wall comprises: 
 mixing an alloying compound with a coating material to form an alloyed mixture; and    depositing the alloyed mixture on the core.    
   
   
       190 . The method of  claim 189 , wherein the alloying compound is a cross-linking agent.  
   
   
       191 . The method of  claim 184 , wherein forming the reactor wall comprises: 
 drying the core; and    wherein forming the reactor wall further comprises applying a film around the core, wherein the film contains at least one of a silicate, a cellulose, chitin, chitosan, polymaleic acid, polyacrylic acid, polyacrylamides, polyvinylalcohols, polyethylene glycols, their respective surrogates.    
   
   
       192 . The method of  claim 191 , wherein the depositing of the coating material is performed after the core is dry.  
   
   
       193 . The method of  claim 184  further comprising shaping a core in a preselected size and shape.  
   
   
       194 . The method of  claim 184 , wherein the reactant is at least one of potassium persulfate, sodium persulfate, ammonium persulfate, potassium monopersulfate, permanganate, and a Caro's acid precursor.  
   
   
       195 . The method of  claim 141 , wherein the target product is an N-halo-amine and wherein preparing the core comprises: 
 combining an oxidant in an amount of about 10-80 wt. % of the core, a halogen donor in an amount of about 0.5-20 wt. % of the core, a stabilizer in an amount of about 2-50 wt. % of the core, a binder in an amount of about 0-50 wt. % of the core, a filler in an amount of about 0-50 wt. % of the core, and a pH buffering agent in an amount of about 0-30 wt. % of the core such that at least about 50 wt. % of the core is solids.    
   
   
       196 . The method of  claim 195 , wherein preparing the core comprises mixing core components to produce an agglomerate.  
   
   
       197 . The method of  claim 195  further comprising: 
 drying the core; and    coating the core with one of: a silicate-based material, a mixture of a polymer and a surfactant, and a porous membrane.    
   
   
       198 . The method of  claim 195 , wherein the reactor wall, upon contact with a polar solvent, allows the solvent to permeate into the reactor space while restricting a diffusion of the reactant and the target product out of the reactor.  
   
   
       199 . The method of  claim 195 , wherein a solubility of the reactor wall in the main solvent is lower than a solubility of the oxidant and the solubility of the target product in the main solvent.  
   
   
       200 . The method of  claim 195 , wherein forming the reactor wall comprises: 
 mixing an alloying compound with a coating material to form an alloyed mixture; and    depositing the alloyed mixture on the core.    
   
   
       201 . The method of  claim 200 , wherein the alloying compound is a cross-linking agent.  
   
   
       202 . The method of  claim 195 , wherein forming the reactor wall further comprises applying a film around the core, wherein the film contains at least one of a silicate, a cellulose, chitin, chitosan, polymaleic acid, polyacrylic acid, polyacrylamides, polyvinylalcohols, polyethylene glycols, their respective surrogates.  
   
   
       203 . The method of  claim 202 , wherein the depositing of the coating material is performed after the core is dry.  
   
   
       204 . The method of  claim 195  further comprising forming the core in a preselected size and shape.  
   
   
       205 . The method of  claim 195 , wherein the reactant is one of potassium persulfate, sodium persulfate, ammonium persulfate, potassium monopersulfate, permanganate, and Caro's acid precursors.  
   
   
       206 . The method of  claim 195 , wherein the halogen donor is one of a monovalent metal salt, divalent metal salt and a trivalent metal salt.  
   
   
       207 . The method of  claim 195 , wherein the core further comprises an N-hydrogen donor capable of reacting with hypo-halite to generate the target product.  
   
   
       208 . The method of  claim 141 , wherein the target product is chlorine dioxide and wherein preparing the core comprises: 
 combining an oxidant in an amount of about 10-80 wt. % of the core, a halogen donor in an amount of about 0.5-20 wt. % of the core, a chlorite donor in an amount of about 0.5-15 wt. % of the core, a binder in an amount of about 0-50 wt. % of the core, a filler in an amount of about 0-50 wt. % of the core, and a pH buffering agent in an amount of about 0-30 wt. % of the core such that at least about 50 wt. % of the core is solids.    
   
   
       209 . The method of  claim 208 , wherein preparing the core comprises mixing core components to produce an agglomerate.  
   
   
       210 . The method of  claim 208  further comprising: 
 drying the core; and    coating the core with one of: a silicate-based material, a mixture of a polymer and a surfactant, and a porous membrane.    
   
   
       211 . The method of  claim 208 , wherein the reactor wall, upon contact with a polar solvent, allows the solvent to permeate into the reactor space while restricting a diffusion of the reactant and the target product out of the reactor.  
   
   
       212 . The method of  claim 208 , wherein a solubility of the reactor wall in the main solvent is lower than a solubility of the oxidant and the solubility of the target product in the main solvent.  
   
   
       213 . The method of  claim 208 , wherein forming the reactor wall comprises: 
 mixing an alloying compound with a coating material to form an alloyed mixture; and    depositing the alloyed mixture on the core.    
   
   
       214 . The method of  claim 213 , wherein the alloying compound is a cross-linking agent.  
   
   
       215 . The method of  claim 208 , wherein forming the reactor wall further comprises applying a film around the core, wherein the film contains at least one of a silicate, a cellulose, chitin, chitosan, polymaleic acid, polyacrylic acid, polyacrylamides, polyvinylalcohols, polyethylene glycols, their respective surrogates.  
   
   
       216 . The method of  claim 215 , wherein the applying of the film is performed after the core is dry.  
   
   
       217 . The method of  claim 208  further comprising shaping a core in a preselected size and shape.  
   
   
       218 . The method of  claim 208 , wherein the reactant is one of urea peroxide, calcium peroxide, magnesium peroxide, sodium percarbonate sodium perborate, persulfate(s), monopersulfate, persilicate, perphosphate, sodium, lithium, potassium peroxide, and permanganate.  
   
   
       219 . The method of  claim 208 , wherein the halogen donor is one of a monovalent or divalent metal salt.  
   
   
       220 . The method of  claim 141 , wherein the target product is hydroxyl radicals and wherein preparing the core comprises: 
 combining an oxidant in an amount of about 10-80 wt. % of the core, transition metal in an amount of about 0.001-10 wt. % of the core, a binder in an amount of about 0-50 wt. % of the core, a filler in an amount of about 0-50 wt. % of the core, and a pH buffering agent in an amount of about 1-30 wt. % of the core such that at least about 50 wt. % of the core is solids.    
   
   
       221 . The method of  claim 220 , wherein preparing the core comprises mixing core components to produce an agglomerate.  
   
   
       222 . The method of  claim 220  further comprising: 
 drying the core; and    coating the core with one of: a silicate-based material, a mixture of a polymer and a surfactant, and a porous membrane.    
   
   
       223 . The method of  claim 222 , wherein the film comprises a metal catalyst for the chemical reaction.  
   
   
       224 . The method of  claim 223  further comprising: 
 combining the metal catalyst with a non-solvent component to generate a catalyst mixture;    applying the catalyst mixture on the core to form the reactor wall; and    removing the non-solvent component, leaving pores in the reactor wall including the metal catalyst.    
   
   
       225 . The method of  claim 220 , wherein the reactor wall, upon contact with a polar solvent, allows the solvent to permeate into the reactor space while restricting a diffusion of the reactant and the target product out of the reactor.  
   
   
       226 . The method of  claim 220 , wherein a solubility of the reactor wall in the main solvent is lower than a solubility of the oxidant and the solubility of the target product in the main solvent.  
   
   
       227 . The method of  claim 220 , wherein forming the reactor wall comprises: 
 mixing an alloying compound with a coating material to form an alloyed mixture; and    depositing the alloyed mixture on the core.    
   
   
       228 . The method of  claim 227 , wherein the alloying compound is a cross-linking agent.  
   
   
       229 . The method of  claim 220 , wherein forming the reactor wall further comprises applying a film around the core, wherein the film contains at least one of a silicate, a cellulose, chitin, chitosan, polymaleic acid, polyacrylic acid, polyacrylamides, polyvinylalcohols, polyethylene glycols, their respective surrogates.  
   
   
       230 . The method of  claim 228 , wherein the applying the film is performed after the core is dry.  
   
   
       231 . The method of  claim 220  further comprising shaping a core in a preselected size and shape.  
   
   
       232 . The method of  claim 220 , wherein the reactant is one of urea peroxide, calcium peroxide, magnesium peroxide, sodium percarbonate sodium perborate, persulfate(s), monopersulfate, persilicate, perphosphate, sodium, lithium, and potassium peroxide.  
   
   
       233 . The method of  claim 220 , wherein the transition metal is a chelating agent selected from a group consisting of trisodium pyrophosphate, tetrasodium diphosphate, sodium hexametaphosphate, sodium trimetaphosphate, sodium tripolyphosphate, potassium tripolyphosphate, phosphonic acid, di-phosphonic acid compound, tri-phosphonic acid compound, a salt of a phosphonic acid compound, ethylene diamine-tetra-acetic acid, gluconate, or other ligand forming compound.  
   
   
       234 . The method of  claim 220  further comprising adding a metal catalyst to the reactor, wherein the metal catalyst is one of Cu (II), Mn (II), Co (II), Fe (II), Fe (III), Ni (II), Ti (IV), Mo (V), Mo (VI), W (VI), Ru (III), and Ru (IV).