Fluid processing device and method

A vaporizer comprising:

• a stack of thin sheets integrally bonded, the stack including alternating recessed sheets having holes at opposing ends wherein the recesses in the sheets define at least a portion of first and second distinct flow paths;
• wherein the first flow paths are operable to convey a vaporizing fluid between the holes and include a liquid flow portion in communication with a vapor flow portion having a cross sectional area substantially greater than the cross sectional area of the liquid flow portion, the liquid flow portion including at least one tortuous microchannel;
• wherein the second flow paths are separate from the holes and in thermal contact with at least a portion of the vapor flow portion of the first flow paths.

A method of vaporizing a liquid comprising:

• flowing a first stream including liquid through a plurality of first vaporization microchannels each including a liquid flow portion in fluid communication with a vapor flow portion having a cross sectional area substantially greater than the cross sectional area of the liquid flow portion;
• heating the first stream with a second fluid flowing through second heat exchange microchannels in thermal contact with the first vaporization microchannels to vaporize at least a portion of the first stream;
• wherein the Reynolds number of the flow of the second fluid in the second heat exchange microchannels is less than about 1000 and the pressure drop of the second fluid through the second heat exchange microchannels in inches of water is less than about 10 times the inverse of the pressure of the second fluid in atmospheres at an inlet to the second heat exchange microchannels.

A method comprising:

• forming a plurality of individual fluid processing units together and then separating the units after some degree of assembly into individual units;
• wherein forming the plurality of individual units together includes forming integral metal-to-metal bonds in a stack of thin metal sheets, the stack including alternating recessed sheets wherein the recesses in the sheets define at least a portion of flow paths for the individual fluid processing units, and
• wherein the width of the individual units after the separation is substantially less than the height of the stack of thin metal sheets.

A method for vaporizing a liquid to produce superheated vapor:

• flowing a first stream including liquid through a plurality of first vaporization microchannels disposed between a macrochannel inlet and a macrochannel outlet, each vaporization microchannel including a liquid flow portion in fluid communication with a vapor flow portion having a cross sectional area substantially greater than the cross sectional area of the liquid flow portion;
• vaporizing and substantially superheating the first stream in the first vaporization microchannels by heating the first stream with a second fluid flowing through second heat exchange microchannels in thermal contact with the first vaporization microchannels along the microchannel flow length of the first vaporization microchannels.

A method comprising:

• providing a stack of thin sheets integrally bonded, the stack including a plurality of recessed sheets having holes at opposing ends wherein the recesses in the sheets define at least a portion of a plurality of generally parallel first vaporization flow paths operable to convey a vaporizing fluid between the holes and including a liquid flow portion in communication with a vapor flow portion having a cross sectional area substantially greater than the cross sectional area of the liquid flow portion, the liquid flow portions of each of the first vaporization flow paths including at least one tortuous microchannel for establishing a pressure drop through the liquid flow portion of the first vaporization flow paths;
• flowing a first fluid containing liquid into each of the first vaporization flow paths while maintaining a sufficient pressure drop in the liquid flow portions to control distribution of the first fluid to each of the first vaporization flow paths;
• while flowing the first fluid, heating the first fluid to vaporize at least a portion of the liquid while in the vapor flow portions.