Multiphase mixing process using microchannel process technology

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having one or more interior walls with surface features formed in and/or on one or more of the interior walls for modifying flow within the process microchannel;
• contacting the first fluid stream with a second fluid stream within the process microchannel to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase, the multiphase mixture flowing in the process microchannel and contacting the surface features, the flow of the multiphase mixture within the process microchannel being modified by contacting the surface features.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the process microchannel comprises two or more apertured sections and separate second fluid streams flow through each of the apertured sections.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the apertured section comprises a relatively thin sheet overlying a relatively thick sheet or plate, the relatively thin sheet containing a plurality of relatively small apertures, and the relatively thick sheet or plate containing a plurality of relatively large apertures, the relatively small apertures being aligned with the relatively large apertures sufficiently to permit gas to flow from the relatively large apertures through the relatively small apertures.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section, wherein the apertured section is made from a porous material;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the apertured section is made from a porous material, the surface of the porous material being treated by filling the pores on the surface with a liquid filler, solidifying the filler, grinding and/or polishing the surface, and removing the filler.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the discontinuous phase is in the form of gas bubbles having a volume-based mean diameter in the range of up to about 25 microns, and a span in the range from about 1.9 to about 2.5.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the discontinuous phase comprises microbody having a volume-based mean diameter in the range up to about 5 microns, and a span in the range from about 1.8 to about 2.5.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the first fluid stream comprises an organic liquid.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the first fluid stream comprises at least one gas.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the second fluid stream comprises at least one gas.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the second fluid stream comprises air, hydrogen, nitrogen, carbon dioxide, or a mixture of two or more thereof.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the second fluid stream comprises a microbody forming material, the polymeric microbody forming material comprising a (meth)acrylate ester of an alcohol of 1 to about 14 carbon atoms.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the second fluid stream comprises a microbody forming material, the polymeric microbody forming material comprising at least one alkyl (meth)acrylate.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein heat is exchanged between the process microchannel and a heat source and/or heat sink, the heat source and/or heat sink comprising at least one heat exchange channel.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein heat is exchanged between the process microchannel and a heat source and/or heat sink, the heat source and/or heat sink comprising an electric heating element and/or resistance heater.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein heat is exchanged between the process microchannel and a heat source and/or heat sink, the heat source and/or heat sink comprising a non-fluid cooling element.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the multiphase mixture comprises at least one liquid hydrocarbon.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the multiphase mixture comprises at least one natural oil, synthetic oil, or mixture thereof.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the multiphase mixture comprises at least one liquid derived from a vegetable source, a mineral source, or mixture thereof.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the multiphase mixture comprises microbodies, the microbodies being hollow.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the multiphase mixture comprises microbodies, the microbodies comprising glass microspheres.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein pigment is dispersed in the multiphase mixture.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein a catalyst is dispersed in the multiphase mixture.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein optical or thermal-optical features of the multiphase mixture are adjusted in the process microchannel.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the second fluid stream flows from a second fluid stream channel through the apertured section, the second fluid stream channel comprising surface features formed in and/or on one or more interior walls for modifying flow within the second fluid stream channel.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the multiphase mixture comprises solid particles dispersed in the first and/or second fluid stream and is in the form of a fluidized bed, the process microchannel comprising surface features formed in and/or on one or more of its interior walls of the process microchannel for modifying flow within the process microchannel.

A process for making a multiphase mixture, comprising:

• flowing a first fluid stream in a process microchannel, the first fluid stream comprising at least one liquid and/or at least one gas, the process microchannel having an apertured section;
• flowing a second fluid stream through the apertured section into the process microchannel in contact with the first fluid stream to form the multiphase mixture, the second fluid stream comprising at least one gas and/or at least one microbody-forming material, the first fluid stream forming a continuous phase in the multiphase mixture, the second fluid stream forming a discontinuous phase dispersed in the continuous phase;
• wherein the multiphase mixture is in the form of a foam.