Methods for using parallel flow reactor having improved thermal control

Abstract

Parallel flow chemical processing systems, such as parallel flow chemical reaction systems are disclosed. These systems are adapted to simultaneously and independently vary temperature between separate flow channels, preferably by employing separate, individual heating elements in thermal communication with each of four or more parallel flow reactors. The flow reactors are preferably isolated from each other using a thermal isolation system comprising fluid-based heat exchange. In preferred embodiments, the axial heat flux can be fixedly or controllably varied.

Description

[0001] This application is a divisional of U.S. application Ser. No. 10 / 094,257 filed on Mar. 7, 2002, which claims priority to co-owned, U.S. Ser. No. 60 / 274,065 entitled “Parallel Flow Reactor Having Improved Thermal Control” filed Mar. 7, 2001 by Bergh et al. both of which are incorporated herein by reference for all purposes.BACKGROUND OF INVENTION [0002] The present invention generally relates to materials science research, and specifically, to combinatorial (i.e., high throughput) materials science research directed toward the identification and / or optimization of new materials. The invention particularly relates, in preferred embodiments, to apparatus and methods for optimizing chemical reaction systems, such as chemical reaction systems involving heterogeneous catalysts. [0003] In recent years, significant efforts have been extended toward developing parallel systems, such as parallel reactors, for the purpose of screening different materials, such as heterogeneous catalysts...

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Benefits of technology

[0007] It is therefore an object of the present invention to provide apparatus and methods for more efficient identification and / or optimization of materials and / or temperature conditions in chemical processing systems (e.g., chemical reaction systems), where temperature can be independently significant with respect to performance in the application of interest.

[0009] The invention is directed, in one embodiment, to parallel reaction systems having the capability to simultaneously and independently vary temperature between separate channels. The parallel flow reaction systems can generally include a reactor module that comprises four or more parallel flow reactors having separate and independent temperature control for each of the four or more reactors. Preferably, the temperature control system is adapted to provide individually variable temperature differences of at least about 5° C., preferably at least about 10° C. as compared between four or more spatially adjacent reactors. Advantageously, in some embodiments, the thermal control system of the reaction system is capable of providing even higher temperature differences between spatially adjacent reactors—such as at least about 20° C., at least about 50° C., at least about 100° C., at least about 150° C. or at least about 200° C.

Problems solved by technology

More specifically for example, in the context of heterogeneous catalysis research, only limited attention has been focused on the development of apparatus and methods for high-throughput, parallel optimization of important parameters such as catalyst (or catalyst precursor) processing conditions and reaction conditions.

These and other reactor designs known in the art do not, however, specifically address approaches or contemplate apparatus for investigating and / or optimizing reaction temperature—simultaneously and independently—in relatively closely-packed, highly parallel reactors.

As reactor dimensions become reduced, and as the spatial density of reactors increases, significant thermal cross-talk between reaction vessels can be a substantial obstacle for achieving simultaneous and independent temperature control in such reaction systems.

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