A microchannel reactor and a preparation method thereof

Abstract

The present invention provides a microchannel reactor and a preparation method thereof. The microchannel reactor includes a feed pipe, a microchannel assembly, and a discharge pipe. The feed pipe and the discharge pipe are respectively connected to both ends of the microchannel assembly. The microchannel assembly includes a plurality of interconnected mixing units. Feed channels and discharge channels are respectively formed at both ends of the mixing unit. A flow guiding member for diverting fluid raw materials is arranged inside the mixing unit, and a diversion channel is formed between the flow guiding member and the mixing unit. One ends of at least two diversion channels are all connected to the feed channel, and the other ends of the diversion channels are all connected to the discharge channel. Due to the provision of the feed pipe, the microchannel assembly, and the discharge pipe, and the microchannel assembly including a plurality of interconnected mixing units, the fluid raw materials enter the plurality of mixing units from the feed pipe, are fully mixed, and then flow out through the discharge pipe, making the whole reaction sufficient, efficient, and controllable. Through the combined use of the flow guiding member and the principle channel, the fluid raw materials are mixed more uniformly.

Description

Technical Field

[0001] The present invention relates to the technical field of microchannel reactors, and particularly to a microchannel reactor and a preparation method thereof. Background Art

[0002] A microchannel reactor is a device that uses micron-sized channels for chemical reactions. It has the advantages of small volume, fast reaction speed, high efficiency, and low energy consumption, so it is widely used in the fields of chemical engineering, pharmaceuticals, environmental protection, etc. In existing microchannel reactors, reactants flow through the microchannels, and the reactants come into contact with each other in the microchannels and react. Due to the small channel size of the microchannel reactor, the contact area between the reactants is large, the reaction rate is fast, and the reaction efficiency is also higher.

[0003] The microchannels of existing microchannel reactors are usually serpentine microchannels, which are composed of straight channels and turning channels. Although it can make the reactants flow smoothly in the microchannels and reduce the space layout, since there is no obstruction during the flow of the reactants, the collision frequency between the reactants decreases, resulting in uneven mixing between the reactants, and then leading to a problem of decreased chemical reaction efficiency between the reactants. At the same time, it will also cause difficulties in controlling the flow rate of the reactants in the channel, and then lead to safety problems such as incomplete reaction between the reactants and uncontrollable reaction process. In addition, during the process of increasing the volume of the microchannel reactor, a scale-up effect will also occur. Summary of the Invention

[0004] The purpose of the present invention is to provide a microchannel reactor and a preparation method thereof, which effectively solve the problems of existing microchannel reactors. Due to the lack of obstruction during the flow of reactants, the collision frequency between the reactants decreases. Therefore, there are problems of uneven mixing between the reactants and decreased chemical reaction efficiency between the reactants. At the same time, there are also safety problems such as difficulty in controlling the flow rate of the reactants, incomplete reaction between the reactants, and uncontrollable reaction process. Moreover, during the process of increasing the volume of the microchannel reactor, technical problems such as a scale-up effect will also occur.

[0005] To solve the above technical problems, in the first aspect, the present invention provides a microchannel reactor, which includes a feed pipe, a microchannel assembly, and a discharge pipe. The feed pipe and the discharge pipe are respectively connected to both ends of the microchannel assembly; the microchannel assembly includes a plurality of interconnected mixing units; both ends of the mixing unit are respectively provided with a feed channel and a discharge channel. A flow guiding member for diverting the fluid raw material is arranged inside the mixing unit, and a diversion channel is formed between the flow guiding member and the mixing unit. One ends of at least two diversion channels are all connected to the feed channel, and the other ends of the diversion channels are all connected to the discharge channel.

[0006] Further, a first notch is provided at one end of the flow guide member close to the feed channel, and a counter-jet port is provided on the side wall of the mixing unit close to the diversion channel. The counter-jet ports are respectively provided on both sides of the feed channel, and the opening direction of the counter-jet port is opposite to the opening direction of the first notch.

[0007] Further, a second notch is provided at one end of the flow guide member close to the discharge channel, and a convex block is provided on the side wall of the mixing unit close to the discharge channel. The convex blocks are respectively provided on both sides of the discharge channel, and a reflux groove is formed between the convex block and the second notch. One end of the reflux groove is communicated with the diversion channel, and the other end is communicated with the discharge channel.

[0008] Further, the first notch and the second notch are axially symmetrically arranged.

[0009] Further, a plurality of counter-jet members are spaced apart from each other inside the reflux groove; the transverse cross-section of the counter-jet member is any one of circular, triangular, rectangular, and polygonal.

[0010] Further, the transverse cross-sections of the mixing unit and the flow guide member are both elliptical, and two mutually connected diversion channels are formed between the outer wall of the flow guide member and the inner wall of the mixing unit, and the two diversion channels are symmetrically arranged with each other.

[0011] Further, a cavity for heat exchange with the refrigerant channel outside the mixing unit is provided inside the flow guide member.

[0012] Further, a flow disturbance assembly is further provided inside the mixing unit. The flow disturbance assembly is fixed on the diversion channel; the flow disturbance assembly includes a plurality of flow disturbance blocks arranged in a spiral shape, and the plurality of flow disturbance blocks are arranged in sequence along the path of the diversion channel.

[0013] Further, it further includes a housing. A refrigerant cavity is provided inside the housing, and a refrigerant inlet and a refrigerant outlet communicated with the refrigerant cavity are respectively provided at both ends of the housing; the microchannel assembly is arranged in the refrigerant cavity. The discharge end of the feed pipe is communicated with the feed channel, and the feed end of the feed pipe extends to the outside of the housing along the side away from the discharge end; the feed end of the discharge pipe is communicated with the discharge channel, and the discharge end of the discharge pipe extends to the outside of the housing along the side away from the feed end; the feed pipe is arranged in a U shape, and two mutually connected feed ports are provided at the upper end of the feed pipe.

[0014] In a second aspect, the present invention further provides a preparation method of the above-mentioned microchannel reactor, including the following steps:

[0015] S1. Obtain the body structure of the microchannel reactor using 3D drawing software;

[0016] S2. Obtain the structure of the flow disturbance assembly using 3D drawing software;

[0017] S3. Take Hastelloy powder or titanium alloy powder as the printing powder and put it into the powder supply bin of the 3D printer. Then, respectively take the microchannel reactor body structure in step S1 and the flow disturbance component structure in step S2 and import them into the 3D printer. Use 3D printing technology to obtain the microchannel reactor;

[0018] Among them, the powder particle size of the Hastelloy powder or titanium alloy powder is 12 - 55 microns; the 3D printing process parameters of the microchannel reactor body are: laser power is 250 - 450 w, scanning speed is 800 - 1600 mm / s, spacing is 0.10 - 0.15 mm, and layer thickness is 50 - 60 microns; the 3D printing process parameters of the flow disturbance component structure are: laser power is 300 - 500 w, scanning speed is 800 - 1200 mm / s, spacing is 0.10 - 0.12 mm, and layer thickness is 50 - 60 microns; the flow disturbance component structure is printed at a certain angle with the diversion channel of the microchannel reactor body structure, and the angle is less than 50°;

[0019] S4. Take the microchannel reactor in step S3 and place it in a compressed air machine. After removing the powder in the microchannel reactor through the compressed air machine, place it in a heat treatment and conditioning equipment. Then control the heat treatment and conditioning equipment to heat it to above 500°C at a heating rate of 8 - 12°C / min and keep it warm for 1 - 3 h; finally, cool the heat treatment and conditioning equipment to room temperature.

[0020] Adopting the technical solution provided by the present invention, compared with the prior art, it has the following advantages:

[0021] (1) A microchannel reactor provided by the present invention. Since the microchannel reactor is provided with a feed pipe, a microchannel component, and a discharge pipe, and the microchannel component includes a plurality of interconnected mixing units, the fluid raw material can enter the plurality of mixing units from the feed pipe and be fully mixed, and then flow out through the discharge pipe, making the whole reaction sufficient, efficient, and controllable. Moreover, since the microchannel component is composed of a plurality of interconnected mixing units, and the plurality of mixing units are arranged compactly, the amplification effect can be effectively avoided. At the same time, since a flow guiding member for diverting the fluid raw material is provided in a single mixing unit, at least two diversion channels are formed between the flow guiding member and the mixing unit. By the combined use of the flow guiding member and the diversion channels, the fluid raw material is respectively diverted into different diversion channels after being diverted, and re - mixed and converged after flowing through the diversion channels. This can not only make the fluid raw material mix evenly and enhance the mixing effect, but also greatly improve the chemical reaction efficiency.

[0022] (2) A microchannel reactor provided by the present invention has a first notch disposed at one end of the flow guide close to the feed channel, and a counter-offset is disposed on the side wall of the mixing unit close to the diversion channel. Through the cooperation between the first notch and the counter-offset, when the fluid raw material impacts the first notch of the flow guide, it can be separated along both sides of the first notch, so that the fluid raw material is diverted into multiple strands. The diverted fluid raw material is respectively backwashed to the two counter-offsets along the two ends of the first notch, and under the guidance of the counter-offset, a part of the fluid raw material enters the diversion channel, and the other part of the fluid raw material is guided to form a flush with the fluid raw material coming out of the feed channel, so as to perform a strong mixing, and after mixing, the flow guide is impacted again, and the reciprocating cycle is performed, so that the fluid raw materials are fully mixed and the mixing effect is improved.

[0023] (3) The present invention provides a microchannel reactor, in which a second recess is provided at one end of the guide member near the discharge channel, and a protrusion is provided on the side wall of the mixing unit near the discharge channel, and a reflux groove is formed between the protrusion and the second recess. Through the coordinated use of the second recess and the protrusion, the fluid raw material can be strongly mixed in the reflux groove after flowing through the diversion channel, thereby further improving the mixing effect.

[0024] (4) The present invention provides a microchannel reactor, which has a plurality of mutually spaced counter-shock members arranged inside a reflux groove, so that after the fluid raw material flows through the diversion channel, under the action of the counter-shock members, a part of it will be counter-charged with the second recess and mixed in the reflux groove; the other part will reflux and mix to form a flushing, thereby performing a strong mixing, and after mixing, the counter-shock members will be impacted again, and the reciprocating cycle will effectively improve the mixing effect of the fluid raw material.

[0025] (5) In a microchannel reactor provided by the present invention, since the transverse cross-sections of the mixing unit and the flow guide are both elliptical, the flow diversion channels on both sides of the flow guide are arc-shaped, which is conducive to reducing the flow rate of the fluid raw material and reducing the impact force. In addition, the space of the flow diversion channel is large, which can effectively prevent the pressure of the mixing unit from getting out of control.

[0026] (6) The microchannel reactor provided by the present invention has a cavity inside the guide member, so that the heat generated by the chemical reaction in the mixing unit can be exchanged with the refrigerant channel outside the mixing unit through the cavity, thereby preventing the temperature in the mixing unit from being too high and greatly improving the heat dissipation effect.

[0027] (7) A microchannel reactor provided by the present invention has a turbulent assembly in the mixing unit, which is fixed on the diversion channel and is used to divide and mix the fluid raw materials flowing through the diversion channel for multiple times to improve the mixing effect.

[0028] (8) The microchannel reactor provided by the present invention has a housing, and there is a sufficiently large refrigerant space inside the housing, which greatly improves the heat transfer performance.

[0029] (9) A method for preparing the microchannel reactor provided by the present invention directly integrally forms Hastelloy powder or titanium alloy powder with high strength, high corrosion resistance and high heat resistance into a microchannel reactor by using 3D printing technology. This not only improves production efficiency and enables more precise channel design, but also enhances the performance and safety of the microchannel reactor. Compared with the microchannel reactor assembled and welded by the prior art, the prepared microchannel reactor has the advantages of high pressure resistance, strong corrosion resistance and good sealing performance, and thus can be applied to chemical reactions with large heat release. In addition, by setting different 3D printing parameters for the structure of the flow disturbance component and the structure of the microchannel reactor body, and printing the structure of the flow disturbance component at a certain angle with the shunt channel, the quality of the microchannel reactor can be guaranteed, and the collapse of the flow disturbance structure can be avoided. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] To more clearly illustrate the technical solutions of the prior art and the embodiments of the present application, the following will briefly introduce the drawings required for the description of the prior art and the embodiments of the present application. Obviously, the drawings in the following description are only some embodiments recorded in the present application. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0031] Figure 1 It is a sectional view of the combined structure of the feed pipe, the microchannel component and the discharge pipe.

[0032] Figure 2 is Figure 1 a partial enlarged view of part A in

[0033] Figure 3 It is another sectional view of the combined structure of the feed pipe, the microchannel component and the discharge pipe.

[0034] Figure 4 is Figure 3 a partial enlarged view of part B in

[0035] Figure 5 It is a schematic diagram of the combined structure of the feed pipe, the microchannel component and the discharge pipe.

[0036] Figure 6 It is a schematic diagram of the structure of the mixing unit.

[0037] Figure 7 It is a schematic diagram of the structure of the flow disturbance component.

[0038] Figure 8 is for Figure 7Schematic diagram of a symmetric spoiler component structure.

[0039] Figure 9 Schematic diagram of the structure of a microchannel reactor according to the present invention.

[0040] Figure 10 is Figure 9 cross-sectional view of.

[0041] Figure 11 Density detection diagrams of Examples 1 to 9.

[0042] Explanation of reference numerals: Feed pipe 100, microchannel component 200, mixing unit 210, feed channel 211, discharge channel 212, counterflow port 213, flow guide member 220, first notch 221, cavity 222, second notch 223, shunt channel 230, spoiler component 240, spoiler block 241, convex block 250, return groove 260, counterflow member 270, discharge pipe 300, housing 400, refrigerant cavity 410, refrigerant inlet 420, refrigerant outlet 430. Detailed implementation manners

[0043] In order to better understand the purpose, structure and function of the present invention, the following further describes in detail a microchannel reactor and a preparation method thereof provided by the present invention with reference to the accompanying drawings, so that those skilled in the art can better understand the present invention and be able to implement it, but the examples given are not intended to limit the present invention.

[0044] In a first aspect, please refer to Figures 1 to 10 As shown, the present invention provides a microchannel reactor, including a feed pipe 100, a microchannel component 200 and a discharge pipe 300. The feed pipe 100 and the discharge pipe 300 are respectively connected to both ends of the microchannel component 200. The microchannel component 200 includes a plurality of interconnected mixing units 210. Feed channels 211 and discharge channels 212 are respectively provided at both ends of the mixing unit 210. A flow guide member 220 for splitting fluid raw materials is provided inside the mixing unit 210, and a shunt channel 230 is formed between the flow guide member 220 and the mixing unit 210. One ends of at least two shunt channels 230 are all connected to the feed channel 211, and the other ends of the shunt channels 230 are all connected to the discharge channel 212.

[0045] Since the microchannel reactor is provided with a feed pipe 100, a microchannel assembly 200 and a discharge pipe 300, and the microchannel assembly 200 includes a plurality of interconnected mixing units 210, fluid raw materials can enter the plurality of mixing units 210 from the feed pipe 100, be fully mixed, and then flow out through the discharge pipe 300, so that the whole reaction is sufficient, efficient and controllable; moreover, since the microchannel assembly 200 is composed of a plurality of interconnected mixing units 210, and the plurality of mixing units 210 are arranged compactly, the amplification effect can be effectively avoided. At the same time, since a flow guiding member 220 for dividing the fluid raw materials is arranged in a single mixing unit 210, at least two flow dividing channels 230 are formed between the flow guiding member 220 and the mixing unit 210. By the combined use of the flow guiding member 220 and the flow dividing channels 230, the fluid raw materials are divided and then enter different flow dividing channels 230 respectively, and are remixed and converged after flowing through the flow dividing channels 230, which can not only make the fluid raw materials mixed evenly and enhance the mixing effect, but also greatly improve the chemical reaction efficiency.

[0046] Specifically, by connecting the feed pipe 100 with the feed channel 211 of the mixing unit 210, the fluid raw materials enter the interior of the mixing unit 210 through the feed channel 211 of the mixing unit 210 and impact the flow guiding member 220. Under the action of the flow guiding member 220, the fluid raw materials are divided into multiple strands. One strand of the fluid raw materials is guided to form a scour with the fluid raw materials coming out of the feed channel 211, so as to perform a strong mixing, and after the strong mixing, it impacts the flow guiding member 220 again and circulates reciprocally, greatly enhancing the mixing effect; while the other strands of the fluid raw materials are respectively guided into the respective flow dividing channels 230 and impact and converge at the discharge ports of the flow dividing channels 230 to perform a strong mixing again, thereby further enhancing the mixing effect. In addition, since the plurality of mixing units 210 are connected in series with each other, the fluid raw materials after re-convergence enter the next mixing unit 210 from the discharge channel 212 of the mixing unit 210 and repeat the above mixing operation, and so on until flowing out of the discharge pipe 300. Thus, it can be seen that the fluid raw materials are mixed multiple times, so that the fluid raw materials are fully mixed, the mixing effect is enhanced, and the chemical reaction efficiency is greatly improved. At the same time, since the fluid raw materials are fully mixed in the mixing unit 210, the whole reaction is efficient and controllable, and moreover, the mixing units 210 are arranged compactly and can be amplified by series-parallel connection, thereby reducing the amplification effect.

[0047] In a preferred embodiment, the flow guide 220 is provided with a first notch 221 at one end close to the feed channel 211, and the mixing unit 210 is provided with a counter-opening 213 on the side wall close to the diversion channel, and the counter-opening 213 is respectively provided on both sides of the feed channel 211, and the opening direction of the counter-opening 213 is arranged opposite to the opening direction of the first notch 221. The first notch 221 and the counter-opening 213 are both arranged in an arc shape, and the center angle of the circle where the arc of the first notch 221 is located is 90°; the center angle of the circle where the arc of the counter-opening 213 is located is 120°.

[0048] Since the first notch 221 is provided at one end of the flow guide 220 close to the feed channel 211, and the side wall of the mixing unit 210 close to the diversion channel is provided with a counter-punch 213, the first notch 221 and the counter-punch 213 are used in coordination, so that when the fluid raw material impacts the first notch 221 of the flow guide 220, it can be separated along both sides of the first notch 221, so that the fluid raw material is diverted into multiple strands. The diverted fluid raw material is respectively backwashed to the two counter-punch 213 along the two ends of the first notch 221, and under the guidance of the counter-punch 213, a part of the fluid raw material enters the diversion channel 230, and the other part of the fluid raw material is guided to form a flush with the fluid raw material coming out of the feed channel 211, so as to perform a strong mixing, and after mixing, the flow guide 220 is impacted again, and the reciprocating cycle is performed, so that the fluid raw materials are fully mixed and the mixing effect is improved.

[0049] In a preferred embodiment, a second recess 223 is provided at one end of the guide member 220 near the discharge channel 211, and a protrusion 250 is provided on the side wall of the mixing unit 210 near the discharge channel 212. The protrusions 250 are respectively provided on both sides of the discharge channel 212, and a reflux groove 260 is formed between the protrusion 250 and the second recess 223. One end of the reflux groove 260 is connected to the diversion channel 230, and the other end is connected to the discharge channel 212.

[0050] Since a second recess 223 is provided at one end of the guide member 220 close to the discharge channel 211, a protrusion 250 is provided on the side wall of the mixing unit 210 close to the discharge channel 212, and a reflux groove 260 is formed between the protrusion 250 and the second recess 223. Through the cooperation between the second recess 223 and the protrusion 250, the fluid raw material can be strongly mixed in the reflux groove 260 after flowing through the diversion channel 230, thereby further improving the mixing effect.

[0051] In a preferred embodiment, the first notch 221 and the second notch 223 are axially symmetrically arranged, which is beneficial to improving the mixing effect of the fluid raw materials.

[0052] In a preferred embodiment, a plurality of counter - impact members 270 are further disposed inside the reflux tank 260 at intervals; the transverse cross - section of the counter - impact member 270 is set in any one of a circular shape, a triangular shape, a rectangular shape, and a polygonal shape.

[0053] By arranging a plurality of counter - impact members 270 at intervals inside the reflux tank 260, when the fluid raw material flows through the diversion channel 230, under the action of the counter - impact member 270, a part forms a counter - impact with the second notch 223 and is mixed inside the reflux tank 260; another part forms a back - flow mixture to form a scour, so as to perform a strong mixing once, and after mixing, it impacts the counter - impact member 270 again, and circulates reciprocally, effectively improving the mixing effect of the fluid raw material.

[0054] In a preferred embodiment, the transverse cross - sections of the mixing unit 210 and the guiding member 220 are both elliptical, and two mutually - communicating diversion channels 230 are formed between the outer wall of the guiding member 220 and the inner wall of the mixing unit 210, and the two diversion channels 230 are symmetrically arranged with respect to each other.

[0055] Since the transverse cross - sections of the mixing unit 210 and the guiding member 220 are both elliptical, the diversion channels 230 on both sides of the guiding member 220 are arc - shaped, which is beneficial to reducing the flow rate of the fluid raw material and reducing the impact force. Moreover, the space of the diversion channel 230 is relatively large, which can effectively prevent the pressure in the mixing unit 210 from getting out of control.

[0056] In a preferred embodiment, a cavity 222 for heat exchange with the refrigerant channel outside the mixing unit 210 is provided inside the guiding member 220.

[0057] Since the cavity 222 is provided inside the guiding member 220, the heat generated by the chemical reaction inside the mixing unit 210 can be heat - exchanged through the cavity 222 with the refrigerant channel outside the mixing unit 210, so that the temperature inside the mixing unit 210 will not be too high, greatly improving the heat dissipation effect.

[0058] In a preferred embodiment, a flow - disturbing assembly 240 is further provided inside the mixing unit 210, and the flow - disturbing assembly 240 is fixed on the diversion channel 230; the flow - disturbing assembly 240 includes a plurality of flow - disturbing blocks 241 arranged in a spiral shape, and the plurality of flow - disturbing blocks 241 are arranged in sequence along the path of the diversion channel 230. Among them, the flow - disturbing assembly 240 is used to divide and mix the fluid raw material flowing through the diversion channel 230 multiple times to improve the mixing effect.

[0059] Specifically, the spoiler block 241 is formed by twisting a metal plate by 90° into a spiral shape. As a preferred embodiment, five spoiler blocks 241 are provided, and the five spoiler blocks 241 are arranged in the diversion channel 230 at a certain angle in sequence. When the fluid raw material flows through the spoiler block 241, due to the obstruction of the spoiler block 241, it will flow through both sides of the spoiler block, that is, it will be divided once, and thus be divided into two streams of fluid. When flowing through the next spoiler block 241, the two streams of fluid will be divided again. Although it is still two streams of fluid after division, the actual meaning is that it is divided four times. And the spoiler assembly 240 is composed of five spoiler blocks 241, and the fluid raw material will be divided into 2 to the 5th power times. Therefore, the mixing effect is greatly enhanced.

[0060] In a preferred embodiment, it further includes a housing 400. A refrigerant chamber 410 is provided inside the housing 400, and a refrigerant inlet 420 and a refrigerant outlet 430 communicating with the refrigerant chamber 410 are respectively provided at both ends of the housing 400; the microchannel assembly 200 is disposed in the refrigerant chamber 410, the discharge end of the feed pipe 100 communicates with the feed channel 211, and the feed end of the feed pipe 100 extends to the outside of the housing 400 along the side away from the discharge end; the feed end of the discharge pipe 300 communicates with the discharge channel 212, and the discharge end of the discharge pipe 300 extends to the outside of the housing 400 along the side away from the feed end;

[0061] The feed pipe 100 is arranged in a U shape, and two communicating feed ports are provided at the upper end of the feed pipe 100. Among them, multiple feed pipes 100 and discharge pipes 300 can be provided. After the fluid raw materials enter from the two feed ports of the feed pipe 100 respectively, they impact and converge at the discharge port of the feed pipe 100 to achieve a strong mixing once.

[0062] Since the refrigerant chamber 410 is provided in the housing 400, and the refrigerant chamber 410 communicates with the refrigerant inlet 420 and the refrigerant outlet 430 respectively, a refrigerant channel for cooling the microchannel assembly 200 is formed. In addition, the distance between the inner side wall of the housing 400 and the outer side wall of the microchannel assembly 200 is 5-10 mm, and there is a certain gap between the mixing units 210, so that there is a large enough refrigerant space inside the housing 400, greatly improving the heat transfer performance.

[0063] The working principle of a microchannel reactor provided by the present invention is as follows:

[0064] The fluid raw material enters from the two feeding ports of the feeding pipe 100 and impacts and converges at the discharging port of the feeding pipe 100 to achieve the first strong mixing. Since the caliber of the feeding channel 211 is small, the flow rate of the mixed raw material becomes faster after flowing through the feeding channel 211 and will be split into multiple strands after impacting on the first notch 221 of the flow guiding member 220. Since the two sharp corners at both ends of the first notch 221 are oppositely arranged with two pairs of impact ports 213 respectively, the split raw material is respectively backflushed to the two pairs of impact ports 213 along the two ends of the first notch 221. Under the guidance of the impact ports 213, a part of the raw material forms a scour with the raw material coming out of the feeding channel 211 to achieve the second strong mixing, and impacts on the flow guiding member 220 again after mixing, circulating reciprocally; another part of the raw material is guided into the shunt channel 230. Since the space of the shunt channel 230 is large, the flow rate of the raw material decreases and the impact force reduces. Moreover, since a plurality of flow disturbing blocks 241 are arranged in the shunt channel 230, when the fluid raw material flows through the flow disturbing blocks 241, due to the obstruction of the flow disturbing blocks 241, it will flow through both sides of the flow disturbing block, that is, it is divided once, and thus is divided into two strands of fluid. When flowing through the next flow disturbing block 241, the two strands of fluid will be divided again. Although it is still two strands of fluid after division, the actual meaning is that it is divided four times. By analogy, the number of times the raw material is divided increases exponentially to achieve the third strong mixing. When the raw material flows through the shunt channel 230, under the action of the convex block 250, a part forms a counterflush with the second notch 223 and is mixed in the reflux groove 260; another part forms a reflux and mixing scour under the action of the counterflush member 270, so as to perform a strong mixing, and impacts on the counterflush member 270 again after mixing, circulating reciprocally to achieve the fourth strong mixing. Since the microchannel assembly 200 is connected in series among a plurality of mixing units 210, the re-converged raw material enters the next mixing unit 210 from the discharging channel 212 of the mixing unit 210 and repeats the above mixing operation. By analogy, it flows out of the discharging pipe 300 until it does. In addition, by arranging the microchannel assembly 200 in the housing 400 and inputting refrigerant into the interior of the housing 400 through the refrigerant inlet 420, the microchannel assembly 200 is cooled down.

[0065] In a second aspect, the present invention also provides a preparation method of the above-mentioned microchannel reactor, comprising the following steps:

[0066] S1. Obtain the body structure of the microchannel reactor by using three-dimensional mapping software.

[0067] S2. Obtain the structure of the flow disturbing assembly by using three-dimensional mapping software.

[0068] The present invention can accurately obtain the target microchannel reactor by designing the body structure and the flow disturbing structure of the microchannel reactor by using the SolidWorks three-dimensional mapping software.

[0069] S3. Take Hastelloy powder or titanium alloy powder as the printing powder and put it into the powder supply bin of the 3D printer. Then, respectively take the microchannel reactor body structure in step S1 and the flow disturbance component structure in step S2 and import them into the 3D printer, and use 3D printing technology to obtain the microchannel reactor. Among them, the powder particle size of the Hastelloy powder or titanium alloy powder is 12 - 55 microns; the 3D printing process parameters of the microchannel reactor body are: laser power is 250 - 450 w, scanning speed is 800 - 1600 mm / s, spacing is 0.10 - 0.15 mm, and layer thickness is 50 - 60 microns; the 3D printing process parameters of the flow disturbance component structure are: laser power is 300 - 500 w, scanning speed is 800 - 1200 mm / s, spacing is 0.10 - 0.12 mm, and layer thickness is 50 - 60 microns; the flow disturbance component structure is printed at a certain angle with the shunt channel of the microchannel reactor body structure, and the angle is less than 50°.

[0070] In addition, the powder particle size of the Hastelloy powder or titanium alloy powder can also be: one of 12 microns, 15 microns, 32 microns, 53 microns, and 55 microns or the value range between any two of them; the 3D printing process parameters of the microchannel reactor body can also be: one of 250 w, 350 w, and 450 w or the value range between any two of them for laser power, one of 800 mm / s, 1200 mm / s, and 1600 mm / s or the value range between any two of them for scanning speed, one of 0.10 mm, 0.11 mm, 0.13 mm, and 0.15 mm or the value range between any two of them for spacing, and one of 50 microns, 55 microns, and 60 microns or the value range between any two of them for layer thickness; the 3D printing process parameters of the flow disturbance component structure can also be: one of 300 w, 400 w, and 500 w or the value range between any two of them for laser power, one of 800 mm / s, 1000 mm / s, and 1200 mm / s or the value range between any two of them for scanning speed, one of 0.10 mm, 0.11 mm, and 0.12 mm or the value range between any two of them for spacing, and one of 50 microns, 55 microns, and 60 microns or the value range between any two of them for layer thickness;

[0071] In the present invention, Hastelloy powder or titanium alloy powder with high strength, high corrosion resistance and high heat resistance is directly integrally formed into a microchannel reactor by adopting 3D printing technology. This not only improves production efficiency and enables more precise channel design, but also enhances the performance and safety of the microchannel reactor. Compared with the microchannel reactor assembled by welding in the prior art, the prepared microchannel reactor has the advantages of high pressure resistance, strong corrosion resistance and good sealing performance, and thus can be applied to chemical reactions with large heat release. In addition, by setting different 3D printing parameters for the structure of the flow disturbance component and the structure of the microchannel reactor body, and printing the structure of the flow disturbance component at a certain angle with the diversion channel, the quality of the microchannel reactor can be ensured and the collapse of the flow disturbance structure can be avoided.

[0072] S4. Place the microchannel reactor obtained in step S3 into a compressed air machine, remove the powder in the microchannel reactor through the compressed air machine, and then place it into a heat treatment and conditioning device. Then, control the heat treatment and conditioning device to heat it to above 500 °C at a heating scanning speed of 8 - 12 °C / min and keep it warm for 1 - 3 h; finally, cool the heat treatment and conditioning device to room temperature. Among them, by performing heat treatment and conditioning on the microchannel reactor, the strength and toughness of the microchannel reactor can be enhanced to improve the pressure-bearing performance of the microchannel reactor.

[0073] Example 1

[0074] Step 1: Use the 3D drawing software SolidWorks to design the structure of the microchannel reactor body and export it in STL format for backup.

[0075] Step 2: Use the 3D drawing software SolidWorks to design the structure of the flow disturbance component and export it in STL format for backup.

[0076] Step 3: Select Hastelloy powder with a powder particle size of 53 microns as the 3D printing powder and add it to the powder supply bin of the EOS M290 laser 3D printer. Then, import the designed microchannel reactor body structure model and the flow disturbance component structure model in steps 1 and 2 into the software equipped with the 3D printer respectively, and set the 3D printing parameters of the microchannel reactor body structure as follows: laser power is 350 w, scanning speed is 1200 mm / s, spacing is 0.10 mm, and layer thickness is 55 microns; set the 3D printing process parameters of the flow disturbance component structure as follows: laser power is 400 w, scanning speed is 1000 mm / s, spacing is 0.10 mm, and layer thickness is 55 microns. After setting the 3D printing process parameters, use the EOS M290 laser 3D printer to print the microchannel reactor body structure and the flow disturbance component structure simultaneously.

[0077] Step 4: Blow out the excess powder in the microchannel reactor printed in Step 3 with compressed air, and place the whole into a heat treatment and conditioning equipment for heat treatment. Then, control the heat treatment and conditioning equipment to heat it to 800 °C at a heating rate of 10 °C / min, hold for 2 h, and then cool it to room temperature with the heat treatment and conditioning equipment.

[0078] Step 5: After cutting the heat-treated microchannel reactor with a wire cutting machine, machine the inlet and outlet ports of the microchannel reactor to have threads, and use a washing liquid to clean the oil stains inside the microchannel reactor after machining.

[0079] Example 2

[0080] The difference between this example and Example 1 is only the 3D printing parameters of the microchannel reactor body structure. The 3D printing parameters of the microchannel reactor body structure in this example are: laser power is 350 w, scanning speed is 800 mm / s, spacing is 0.10 mm, and layer thickness is 55 microns.

[0081] Example 3

[0082] The difference between this example and Example 1 is only the 3D printing parameters of the microchannel reactor body structure. The 3D printing parameters of the microchannel reactor body structure in this example are: laser power is 350 w, scanning speed is 1600 mm / s, spacing is 0.10 mm, and layer thickness is 55 microns.

[0083] Example 4

[0084] The difference between this example and Example 1 is only the 3D printing parameters of the microchannel reactor body structure. The 3D printing parameters of the microchannel reactor body structure in this example are: laser power is 450 w, scanning speed is 1200 mm / s, spacing is 0.10 mm, and layer thickness is 55 microns.

[0085] Example 5

[0086] The difference between this example and Example 1 is only the 3D printing parameters of the microchannel reactor body structure. The 3D printing parameters of the microchannel reactor body structure in this example are: laser power is 250 w, scanning speed is 1200 mm / s, spacing is 0.10 mm, and layer thickness is 55 microns.

[0087] Example 6

[0088] The difference between this example and Example 2 is only the 3D printing parameters of the microchannel reactor body structure. The 3D printing parameters of the microchannel reactor body structure in this example are: laser power is 250 w, scanning speed is 800 mm / s, spacing is 0.10 mm, and layer thickness is 55 microns.

[0089] Example VII

[0090] The difference between this example and Example II lies only in the 3D printing parameters of the microchannel reactor body structure. The 3D printing parameters of the microchannel reactor body structure in this example are: laser power is 450w, scanning speed is 800mm / s, spacing is 0.10mm, and layer thickness is 55 microns.

[0091] Example VIII

[0092] The difference between this example and Example III lies only in the 3D printing parameters of the microchannel reactor body structure. The 3D printing parameters of the microchannel reactor body structure in this example are: laser power is 450w, scanning speed is 1600mm / s, spacing is 0.10mm, and layer thickness is 55 microns.

[0093] Example IX

[0094] The difference between this example and Example III lies only in the 3D printing parameters of the microchannel reactor body structure. The 3D printing parameters of the microchannel reactor body structure in this example are: laser power is 250w, scanning speed is 1600mm / s, spacing is 0.10mm, and layer thickness is 55 microns.

[0095] Comparative Example I

[0096] This comparative example provides a WH-IND HJ160 welded metal microreactor.

[0097] Experimental Example

[0098] I. Apparent Density Test:

[0099] Test Objects: The microchannel reactors prepared in Examples I to IX were taken respectively.

[0100] Test Method: An METTLER TOLEDO LE104E electronic balance with a test accuracy of 0.0001g was selected to weigh the mass of the polished microchannel reactor sample in air. After repeating the weighing 3 times and taking the average value, it was marked as M1. The polished sample was put into a beaker filled with about 2 / 3 pure water with tweezers, and the mass M2 when it was completely immersed in pure water was weighed. After drying the water on the surface of the sample, this operation was repeated, and the average value was taken after weighing 3 times. The formula for calculating the apparent density ω is as follows:

[0101] ω = (M1ρ1) / ((M1 - M2)ρ2) (Equation 1)

[0102] Among them, ρ1 in Equation 1 is the density of pure water, 1g / cm 3 , and ρ2 is the density of Hastelloy, 8.44g / cm 3, the theoretical value of the density ω is 100%.

[0103] Please refer to Figure 11 As shown, the density ω results of the microchannel reactor are as follows:

[0104] Example M1 (g) M2 (g) ρ1 (g / cm3) ρ2 (g / cm3) ω (%) Example 1 5.9792 5.2707 1 8.44 99.99 Example 2 5.7108 5.0325 1 8.44 99.76 Example 3 5.9737 5.2563 1 8.44 98.66 Example 4 5.9374 5.2158 1 8.44 97.49 Example 5 6.0284 5.3095 1 8.44 99.36 Example 6 5.8789 5.1804 1 8.44 99.72 Example 7 5.9254 5.2041 1 8.44 97.33 Example 8 5.6952 5.0157 1 8.44 99.30 Example 9 6.1351 5.4042 1 8.44 99.46

[0105] From the above density test results, it can be seen that when the 3D printing parameters of the microchannel reactor body structure are set as: laser power is 350w, scanning speed is 1200mm / s, spacing is 0.10mm, and layer thickness is 55 microns, the prepared microchannel reactor has the best density, and its density can reach 99.99%.

[0106] II. Pressure-bearing test:

[0107] Test objects: The microchannel reactors prepared in Examples 1 to 9 and the WH-IND HJ160 welded metal microreactor in Comparative Example 1 were taken respectively.

[0108] Test method: The liquid was pumped into the microchannel reactor through a plunger pump. The back pressure valve was gradually adjusted. After the pressure was adjusted to 10 Mpa, the plunger pump and the back pressure valve were closed to keep the overall pressure of the microreactor at 10 Mpa for a small test of pressure holding for 8 hours. According to the design pressure, the wall thickness was calculated with reference to the formula in the specification GB50316-2000 <Code for Design of Industrial Metal Piping> and calculated according to the following formula.

[0109] S1 = PD / (2[σ]E + PY)) (Formula 2)

[0110] S = S1 + C1 + C2 (Formula 3)

[0111] Among them, in Formulas 2 and 3, P is the design pressure; S is the design thickness; S1 is the calculated thickness; D1 is the outer diameter of the pipe, D2 is the inner diameter of the pipe, [σ] is the material stress at the design temperature; C1 is the additional amount of material thinning, C2 is the additional amount of corrosion; Y is taken according to the table; E is the welding joint coefficient.

[0112] The final pressure-bearing results of the microchannel reactor are as follows:

[0113] Examples and Comparative Examples Whether deformation occurs Example 1 No Example 2 No Example 3 No Example 4 No Example 5 No Example 6 No Example 7 No Example 8 No Example 9 No Comparative Example 1 Deformation occurs

[0114] From the above pressure-bearing test, it can be seen that the microchannel reactor prepared by the above preparation method has better pressure-bearing performance than the microchannel reactor assembled and welded by the prior art, and the pressure-bearing exceeds 10 Mpa.

[0115] It will be understood that the present invention is described by way of some embodiments, and those skilled in the art will appreciate that various changes or equivalent substitutions may be made to these features and embodiments without departing from the spirit and scope of the present invention. Additionally, under the teaching of the present invention, these features and embodiments may be modified to adapt to specific circumstances and materials without departing from the spirit and scope of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of the present application belong to the scope protected by the present invention.

Claims

1. A microchannel reactor, comprising a feed pipe (100), a microchannel assembly (200) and a discharge pipe (300), wherein the feed pipe (100) and the discharge pipe (300) are respectively connected to two ends of the microchannel assembly (200); characterized in that: The microchannel assembly (200) comprises a plurality of mixing units (210) that are interconnected; a feed channel (211) and a discharge channel (212) are respectively provided at both ends of the mixing unit (210); a flow guide (220) for diverting a fluid raw material is provided inside the mixing unit (210); a diverting channel (230) is formed between the flow guide (220) and the mixing unit (210); one end of at least two of the diverting channels (230) are both connected to the feed channel (211), and the other end of the diverting channel (230) is both connected to the discharge channel (212); A first notch (221) is provided at one end of the flow guide member (220) close to the feed channel (211); a counter-opening (213) is provided on a side wall of the mixing unit (210) close to the flow diversion channel; the counter-openings (213) are respectively provided on both sides of the feed channel (211), and the opening direction of the counter-opening (213) is arranged opposite to the opening direction of the first notch (221); A second notch (223) is provided at one end of the flow guide member (220) close to the discharge channel (212); a protrusion (250) is provided on the side wall of the mixing unit (210) close to the discharge channel (212); the protrusions (250) are respectively provided on both sides of the discharge channel (212); a reflux groove (260) is formed between the protrusion (250) and the second notch (223); one end of the reflux groove (260) is in communication with the diversion channel (230), and the other end is in communication with the discharge channel (212); The first notch (221) and the second notch (223) are arranged axially symmetrically; A plurality of mutually spaced counter-attachment members (270) are further arranged inside the reflux groove (260); the transverse cross-section of the counter-attachment member (270) is in any one of a circular, triangular, rectangular, and polygonal shape; The transverse cross-sections of the mixing unit (210) and the flow guide (220) are both elliptical, and two mutually connected flow diversion channels (230) are formed between the outer wall of the flow guide (220) and the inner wall of the mixing unit (210), and the two flow diversion channels (230) are symmetrically arranged with respect to each other; The flow guide (220) is provided with a cavity (222) inside for performing heat exchange with the refrigerant channel outside the mixing unit (210); A spoiler component (240) is also provided in the mixing unit (210), and the spoiler component (240) is fixed on the diversion channel (230); the spoiler component (240) comprises a plurality of spoiler blocks (241) arranged in a spiral shape, and the plurality of spoiler blocks (241) are arranged in sequence along the channel path of the diversion channel (230).

2. The microchannel reactor according to claim 1, characterized in that: It also includes a shell (400), wherein a refrigerant cavity (410) is provided inside the shell (400), and a refrigerant inlet (420) and a refrigerant outlet (430) which are connected to the refrigerant cavity (410) are provided at both ends of the shell (400); the microchannel assembly (200) is arranged in the refrigerant cavity (410), the discharge end of the feed pipe (100) is connected to the feed channel (211), and the feed end of the feed pipe (100) extends to the outside of the shell (400) along a side away from the discharge end; the feed end of the discharge pipe (300) is connected to the discharge channel (212), and the discharge end of the discharge pipe (300) extends to the outside of the shell (400) along a side away from the feed end; The feed pipe (100) is arranged in a U shape, and the upper end of the feed pipe (100) is provided with two feed ports that are connected to each other.

3. A method for preparing a microchannel reactor according to any one of claims 1 to 2, characterized in that: The following steps are involved: S1. Use three-dimensional mapping software to obtain the main structure of the microchannel reactor; S2. Obtain the spoiler component structure using three-dimensional mapping software; S3, taking Hastelloy powder or titanium alloy powder as printing powder and putting it into the powder supply bin of the 3D printer, and then taking the microchannel reactor body structure in step S1 and the spoiler component structure in step S2 and introducing them into the 3D printer respectively, and obtaining the microchannel reactor by using 3D printing technology; Among them, the powder particle size of Hastelloy powder or titanium alloy powder is 12 ~ 55 microns; the 3D printing process parameters of the microchannel reactor body are: laser power is 250~450w, scanning speed is 800~1600mm / s, spacing is 0.10~0.15mm, and layer thickness is 50~60 microns; the 3D printing process parameters of the spoiler component structure are: laser power is 300~500w, scanning speed is 800~1200mm / s, spacing is 0.10~0.12mm, and layer thickness is 50~60 microns; the spoiler component structure and the diversion channel of the microchannel reactor body structure are printed at a certain angle, and the angle is less than 50°; S4, taking the microchannel reactor in step S3 and placing it in a compressed air machine, removing the powder in the microchannel reactor by the compressed air machine and placing it in a heat treatment tempering equipment, then controlling the heat treatment tempering equipment to heat to above 500° C. at a heating rate of 8 to 12° C. / min, and keeping warm for 1 to 3 hours; finally, cooling the heat treatment tempering equipment to room temperature.

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