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US 7,745,667 B2Granted
Microchannel apparatus comprising structured walls, chemical processes, methods of making formaldehyde
AssigneeVelocys, Inc.
InventorsSoumitra Deshmukh, Anna Lee Tonkovich, Terry Manzanec, Bin Yang, Kai Jarosch, Richard Long, Francis P. Daly
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Abstract
Methods for controlling series or series-parallel reactions are described. Novel microchannel apparatus having mesoporous structures adjacent to bulk flow paths are described. Methods of synthesizing formaldehyde from methanol are also described.
Claims39
A method of conducting a series or series parallel reaction, comprising:
- passing a first reactant into a microchannel;
- passing a second reactant into the microchannel in plural stages;
- wherein the first and second reactant react in each stage;
- wherein the yield of primary product from the method, based on the first reactant, is at least 90%, and wherein, at the end of each stage, the second reactant is not completely consumed but is present in a range of 0.01 to 10 mol %.
1 more element
A method of conducting a series or series-parallel reaction in a reaction chamber, comprising:
- passing a stream comprising a first reactant into a bulk flow path having at least one dimension of 2 mm or less;
- wherein, adjacent to the bulk flow path, there is a catalyst supported on a mesoporous matrix;
- wherein the first reactant reacts with a second reactant on the catalyst that is supported on a mesoporous matrix;
- wherein the volume occupied by the catalyst supported on a mesoporous matrix (wherein the volume occupied by the catalyst includes the volume of the porous support and spaces within the catalyst) plus the volume of bulk flow path that is adjacent to the catalyst supported on a mesporous matrix defines the volume of reaction chamber;
- controlling the flow of reactants such that at least 90% of the stream has a residence time in the reaction chamber that varies by less than 10% of the mass average residence time.
2 more elements
A method of synthesizing formaldehyde in microchannel apparatus, comprising:
- passing methanol into a channel;
- wherein the channel comprises a bulk flow path, a formaldehyde synthesis catalyst supported on a mesoporous matrix adjacent to the bulk flow path, and channel walls comprising plural apertures;
- passing oxygen through the plural apertures;
- wherein the methanol and the oxygen react on the formaldehyde synthesis catalyst;
- wherein the oxygen content is controlled such that the molar % of oxygen does not exceed 10% in any 5 volume % of the channel and wherein the amount (molar) of methanol exceeds the amount of oxygen in any 5 volume % of the channel (where the 5% volume is based a continuous length and covers an entire cross-sectional area over the continuous length);
- and
- producing a product stream comprising formaldehyde in a yield of at least 90% based on the methanol reactant.
4 more elements
A method of synthesizing formaldehyde in microchannel apparatus, comprising:
- passing methanol into a channel;
- wherein the channel comprises a bulk flow path, a formaldehyde synthesis catalyst supported on a mesoporous matrix adjacent to the bulk flow path, and channel walls comprising plural apertures;
- passing oxygen through the plural apertures;
- wherein the methanol and the oxygen react on the formaldehyde synthesis catalyst;
- wherein the oxygen content is controlled such that the concentration of oxygen entering any stage of the microchannel apparatus is greater than 1 molar %;
- wherein the oxygen content is controlled such that the concentration of oxygen exiting any stage of the microchannel apparatus is greater than 0.01 molar %;
- and
- producing a product stream comprising formaldehyde in a yield of at least 90% based on the methanol reactant.
5 more elements
A method of synthesizing formaldehyde in microchannel apparatus, comprising:
- passing methanol into a channel;
- wherein the channel comprises a bulk flow path, a formaldehyde synthesis catalyst supported on a mesoporous matrix adjacent to the bulk flow path, and channel walls comprising plural apertures;
- passing oxygen through the plural apertures;
- wherein the methanol and the oxygen react on the formaldehyde synthesis catalyst;
- wherein the plural apertures are spaced an uneven intervals;
- and
- producing a product stream comprising formaldehyde in a yield of at least 90% based on the methanol reactant.
4 more elements
A method of synthesizing formaldehyde in microchannel apparatus, comprising:
- passing methanol into a channel;
- wherein the channel comprises a bulk flow path, a formaldehyde synthesis catalyst supported on a mesoporous matrix adjacent to the bulk flow path, and channel walls comprising plural apertures;
- passing oxygen through the plural apertures into at least a first stage and a second stage;
- wherein the methanol and the oxygen react on the formaldehyde synthesis catalyst in each of the first and second stages;
- wherein the oxygen content is controlled such that the molar % of oxygen does not exceed 10% in each of the first and second stages;
- and
- producing a product stream comprising formaldehyde in a yield of at least 90% based on the methanol reactant.
4 more elements
A method of synthesizing formaldehyde, comprising:
- passing methanol and oxygen over a catalyst at a temperature of 250° C. or more;
- wherein the catalyst comprises a mixed V, Mo oxide on titania support disposed on mesoporous matrix.
Dependencies are inferred from the claim text.