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US 7,125,540 B1Granted
Microsystem process networks
AssigneeBattelle Memorial Institute
InventorsRobert S. Wegeng, Ward E. TeGrotenhuis, Greg A. Whyatt
Life of this patent
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Abstract
Various aspects and applications of microsystem process networks are described. The design of many types of microsystems can be improved by ortho-cascading mass, heat, or other unit process operations. Microsystems having exergetically efficient microchannel heat exchangers are also described. Detailed descriptions of numerous design features in microcomponent systems are also provided.
Claims64
A microcomponent apparatus for conducting unit operations comprising:
- a microcomponent device comprising a first inlet, first exit, a first array of microchannels, and a second array of microchannels;
- wherein, during operation, a stream enters the first inlet of the microcomponent device and is distributed among said first array of microchannels and a first unit operation is performed on said stream, said stream exiting through the first exit and exiting the microcomponent device;
- a processing device connected to the first exit of the microcomponent device;
- said processing device being capable of modifying said stream by a second unit operation;
- an outlet of the processing device connected to a second inlet of said microcomponent device through a second inlet;
- and
- the second array of microchannels connected to said second inlet and a second exit connected to said second array of microchannels;
- wherein, during operation, said stream re-enters said microcomponent device and is distributed among the second array of microchannels where said first unit operation can again be performed on the stream, and said stream exits through the second exit and exits the microcomponent device;
- and
- comprising plural pairs of microcomponent devices and processing devices, wherein each pair comprises a microcomponent device and a processing device connected in the manner described above.
7 more elements
A microchannel device comprising:
- a first zone, wherein during operation, at least one unit process operation is performed, and that, during operation, functions at a first temperature;
- a second zone that, during operation, functions at a second temperature;
- wherein the first temperature is different than the second temperature;
- and
- a microchannel heat exchanger that is disposed between the first zone and the second zone;
- and
- wherein, during operation, a stream flows from the second zone through the microchannel heat exchanger to the first zone and subsequently flows back through the microchannel heat exchanger to the second zone;
- wherein, during operation, within the microchannel heat exchanger, heat is exchanged between the stream flowing from the second zone to the first zone and the stream flowing from the first zone to the second zone;
- and
- wherein the heat exchanger has a thermal power density of at least 0.6 W per cubic centimeter and an exergetic efficiency of at least 80%.
7 more elements
A microstructure architecture comprising at least two layers:
- a first layer comprising a continuous flow microchannel;
- a second layer adjacent said first layer and comprising at least one flow microchannel;
- wherein said first layer and said second layer are adapted to cooperate to form at least two unit operations;
- and
- wherein said continuous flow microchannel is adapted to form at least a portion of said at least three unit operations.
2 more elements
A microstructure architecture comprising at least two layers:
- a first layer comprising a continuous flow microchannel;
- a second layer adjacent said first layer and comprising at least one flow microchannel;
- wherein said first layer and said second layer are adapted to cooperate to form at least two unit operations;
- and
- wherein said continuous flow microchannel is adapted to form at least a portion of said at least two unit operations;
- the microstructure architecture comprising at least three adjacent flow microchannels;
- wherein said microchannels have a width that is defined by microchannel walls;
- and wherein said microchannel walls have gaps that allow pressure to equalize among the microchannels.
5 more elements
A method of exchanging heat in a microchannel device, comprising:
- providing a first stream in a microchannel that exchanges heat with a second stream, wherein the first stream remains in the microchannel and, subsequently, the first stream exchanges heat with a third stream without leaving the microchannel.
A method of conducting unit operations in microcomponent apparatus comprising:
- performing a first unit operation on a first stream in a first microcomponent device, subsequent to the first unit operation, performing a second, discrete unit operation on the first stream to make a modified stream, then in a second microcomponent device, performing the first unit operation on the modified stream, to accomplish a single unit operation for the same purpose as the first unit operation on the first stream;
- where the first stream is a heat exchange fluid and the first unit operation in a microcomponent cell comprises heat exchange, with heat being transferred from an exothermic process to a first stream to provide cooling;
- and
- wherein the second unit operation modifying first stream comprises cooling said first fluid by transferring heat to a heat sink.
1 more element
A method of conducting unit operations in microcomponent apparatus comprising:
- performing a first unit operation on a first stream in a first microcomponent device, subsequent to the first unit operation, performing a second, discrete unit operation on the first stream to make a modified stream, then in a second microcomponent device, performing the first unit operation on the modified stream, to accomplish a single unit operation for the same purpose as the first unit operation on the first stream;
- where the first stream comprises a heat exchange fluid and the first unit operation in a microcomponent device comprises heat exchange, with heat being transferred from the first stream to provide heat for an endothermic process;
- wherein the second unit operation modifying first stream comprises reheating said first fluid by reheating from a heat source or by adding additional fuel or oxygen and performing combustion reactions.
A method of conducting unit operations in microcomponent apparatus comprising:
- performing a first unit operation on a first stream in a first microcomponent cell, subsequent to the first unit operation, performing a second, discrete unit operation on the first stream to make a modified stream, then in a second microcomponent cell, performing the first unit operation on the modified stream, to accomplish a single unit operation for the same purpose as the a first unit operation on the first stream, where the first stream is comprised of chemical reactants and the first unit operation in a microcomponent cell comprises at least one chemical conversion reaction;
- and
- wherein the second unit operation modifying first stream comprises a chemical separation, with at least one reaction product being preferentially removed from first stream.
A method of conducting unit operations in a microcomponent apparatus comprising:
- passing a stream into a first inlet of a microcomponent device, wherein the microcomponent device comprises a first inlet, first exit, a first array of microchannels, and a second array of microchannels;
- wherein the stream is distributed among said first array of microchannels and a first unit operation is performed on said stream, said stream exiting through the first exit and exiting the microcomponent device;
- passing the stream into a processing device connected to the first exit of the microcomponent device;
- and in said processing device, modifying the stream by a second unit operation;
- wherein the stream exits through an outlet of the processing device connected to a second inlet of said microcomponent device;
- and
- wherein said stream then re-enters said microcomponent device through the second inlet and is distributed among a second array of microchannels where said first unit operation is again performed on the stream, and wherein said stream exits through a second exit connected to said second array of microchannels and exits the microcomponent device;
- wherein the processing device comprises a microchannel reactor having reactor channels interleaved with heat exchange channels, and wherein said second unit operation comprises a chemical reaction.
5 more elements
A method of conducting unit operations in a microcomponent apparatus comprising:
- passing a stream into a first inlet of a microcomponent device, wherein the microcomponent device comprises a first inlet, first exit, a first array of microchannels, and a second array of microchannels;
- wherein the stream is distributed among said first array of microchannels and a first unit operation is performed on said stream, said stream exiting through the first exit and exiting the microcomponent device;
- passing the stream into a processing device connected to the first exit of the microcomponent device;
- and in said processing device, modifying the stream by a second unit operation;
- wherein the stream exits through an outlet of the processing device connected to a second inlet of said microcomponent device;
- and
- wherein said stream then re-enters said microcomponent device through the second inlet and is distributed among a second array of microchannels where said first unit operation is again performed on the stream, and wherein said stream exits through a second exit connected to said second array of microchannels and exits the microcomponent device;
- wherein the microcomponent device is a recuperator.
5 more elements
A method of conducting unit operations in a microchannel device comprising:
- performing at least one unit process operation in a first zone at a first temperature;
- performing at least one unit process operation in a second zone at a second temperature;
- wherein the first temperature is different than the second temperature;
- and
- wherein a microchannel heat exchanger is disposed between the first zone and the second zone;
- and
- wherein a stream flows from the second zone through the microchannel heat exchanger to the first zone and subsequently flows back through the microchannel heat exchanger to the second zone;
- wherein within the microchannel heat exchanger, heat is exchanged between the stream flowing from the second zone to the first zone and the stream flowing from the first zone to the second zone;
- and
- wherein the heat exchanger has a thermal power density of at least 0.6 W per cubic centimeter and an exergetic efficiency of at least 80%.
7 more elements
A method of conducting unit operations in microcomponent apparatus comprising:
- performing a first unit operation on a first stream in a first microcomponent cell, subsequent to the first unit operation, performing a second, discrete unit operation on the first stream to make a first modified stream, then in a second microcomponent cell, performing the first unit operation on the first modified stream, to accomplish a single unit operation for the same purpose as the a first unit operation on the first stream;
- wherein the method further comprises passing a second stream through a third microcomponent cell and conducting a third unit operation on the second stream and subsequently passing the second stream into the first microcomponent cell and, simultaneous with the step of performing a first unit operation on a first stream in a first microcomponent cell, performing a unit operation on the second stream in the first microcomponent cell to make a modified second stream;
- passing the modified second stream into the third microcomponent cell and conducting a unit operation on the modified second stream in the third microcomponent cell;
- passing a third stream through a fourth microcomponent cell and conducting the third unit operation on the third stream and subsequently passing the third stream into the second microcomponent cell and, simultaneous with the step of performing a first unit operation on a first modified stream in the second microcomponent cell, performing a unit operation on the third stream in the second microcomponent cell to make a modified third stream;
- and
- passing the modified third stream into the fourth microcomponent cell and conducting a unit operation on the modified third stream in the fourth microcomponent cell.
3 more elements
Dependencies are inferred from the claim text.