US 7,470,405 B2Granted

Microchannel reactor with active oscillatory forcing

AssigneeBoard of Supervisors of Louisiana State University and Agricultural and Mechanical College

InventorsFrederick Carl Knopf, Virbert Paul Rodriguez

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Abstract

A microchannel reactor is disclosed that provides superior performance for three-phase (gas/liquid/solid-catalyst) reactions. The reactor may be used, for example, in industrial-scale catalysis, e.g., in large-scale chemical production, and also in catalyst screening. Each microchannel in the reactor has a separate micro-outlet to supply gas to the channel. Each microchannel is open on both ends, so that liquid may freely flow through the channels in both directions. Oscillatory forcing is applied to the liquid outside the microreactor. The combined effect of the separate gas inlets for each microchannel, the open nature of the microchannels on both ends, and oscillatory forcing results in highly efficient transport of both gas and liquid through all of the microchannels, promotes efficient mixing, and enhances catalysis.

Claims18

Dependent claims

A device comprising:

(a) a reactor comprising a substrate layer or a plurality of adjacent substrate layers;
wherein:
(i) said substrate layer or layers contain a plurality of channels;
(ii) each channel has an inner diameter between about 0.1 and about 20 mm;
(ii) each channel traverses each substrate layer;
and each channel has a first opening on one side of said reactor and a second opening on another side of said reactor;
such that each channel is adapted to allow liquid to flow into the channel's first opening, to flow substantially unimpeded through the interior of said reactor, and to exit from the channel's second opening;
and such that each channel is adapted to allow liquid to flow into the channel's second opening, to flow substantially unimpeded through the interior of said reactor, and to exit from the channel's first opening;
and
(b) a plurality of inlets, wherein at least one said inlet corresponds to each channel;
wherein each said inlet is located within or immediately adjacent to its corresponding channel;
and wherein each said inlet is adapted to supply a fluid to its corresponding channel;
wherein:
(c) said device is adapted to allow the efficient, oscillating flow of a liquid and a fluid through all of the channels, wherein the liquid and the fluid are not identical;
wherein the flow of the liquid and the flow of the fluid result from oscillations imparted to the liquid, and wherein the flow of liquid through the channels occurs in the absence of a substantial head of liquid pressure above said reactor.

12 more elements

A process for mixing a liquid and a fluid, wherein the liquid and the fluid are not identical;

said process comprising the steps of:
(a) supplying the liquid to a device that comprises:
(i) a reactor comprising a substrate layer or a plurality of adjacent substrate layers;
wherein:
(A) the substrate layer or layers contain a plurality of channels;
(B) each channel has an inner diameter between about 0.1 and about 20 mm;
(C) each channel traverses each substrate layer;
and each channel has a first opening on one side of the reactor and a second opening on another side of the reactor;
such that each channel is adapted to allow liquid to flow into the channel's first opening, to flow substantially unimpeded through the interior of the reactor, and to exit from the channel's second opening;
and such that each channel is adapted to allow liquid to flow into the channel's second opening, to flow substantially unimpeded through the interior of the reactor, and to exit from the channel's first opening;
and
(ii) a plurality of inlets, wherein at least one inlet corresponds to each channel;
wherein each inlet is located within or immediately adjacent to its corresponding channel;
and wherein each inlet is adapted to supply a fluid to its corresponding channel;
(b) supplying the fluid to the inlets;
and
(c) applying and oscillating force to the liquid to cause the liquid to oscillate through the channels in the absence of a substantial head of liquid pressure above the reactor;
wherein the resulting oscillations cause the liquid and the fluid to mix with one another with substantially greater efficiency than the liquid and the fluid would mix in otherwise identical circumstances without the oscillations;
and wherein the liquid and the fluid flow through substantially all the channels.

16 more elements

Dependencies are inferred from the claim text.

Facts

Application: 11/042,439Filed 25 Jan 2005
Published: US 2006/0165570 A127 Jul 2006
Granted: 30 Dec 2008
Term ends: Not estimatedThe source records don’t support an estimate.

Classification16 codes

B01J 19/0093
Chemical, physical or physico-chemical processes in general; Their relevant apparatus: microreactors, e.g. miniaturised or microfabricated reactors
B01J 19/0046
Chemical, physical or physico-chemical processes in general; Their relevant apparatus: sequential or parallel reactions, e.g. for the synthesis of…
B01J 2219/00286
Individual reactor vessels: reactor vessels with top and bottom openings
B01J 2219/00313
Reactor vessels in a multiple arrangement: the reactor vessels being formed by arrays of wells in blocks