Modular metal flow reactor with metal structure capable of reconfigurable process flow, high thermal stability

Abstract

A flow reactor includes: a frame; a jet module supported by the frame; the jet flow modules are arranged between the metal plates one by one in the first direction; a metal insert; and a tightening member extending through the metal plate and the jet module in the first direction. Each fluidic module includes a metal reactive layer having opposing major outer surfaces, a fluid passageway disposed in the metal reactive layer, and a module port extending between the major outer surfaces. The module port includes an intersection port that intersects the fluid passage. Each metal plate is provided with a plate port corresponding to the module port. Each metal insert adjoins a corresponding pair of adjacent spaced apart ports in the first direction such that each intersecting port is adjoined by at least one metal insert. The tightening member compresses the two metal plates and the jet module against the metal insert.

Description

[0001] Cross - reference to related applications

[0002] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 428,229, filed on November 28, 2022, under 35 U.S.C. § 119, the content of which is incorporated herein by reference in its entirety. Technical field

[0003] The present disclosure relates to a metal flow reactor having stacked metal jet modules. Specifically, the present disclosure relates to a metal structure configured to compress the stacked jet modules against interchangeable metal inserts positioned relative to the ports of the jet modules to enable reconfigurable process flow through the reactor, high thermal stability, and high operating pressure. Background art

[0004] Many conventional flow reactors include jet modules formed of glass and / or ceramic (with metal - free connections). The boundary conditions of such conventional flow reactors may be limited to a maximum temperature of about 200 °C and a maximum operating pressure of about 18 bar. Some chemicals may benefit from higher operating pressures. Therefore, it would be advantageous to develop a metal flow reactor capable of operating at such higher operating pressures. Summary of the invention

[0005] Aspects of the present disclosure relate to a metal flow reactor and methods of manufacturing and using the same. The metal flow reactor disclosed herein includes a metal structure that enables reconfigurable process fluid flow, high thermal stability, and extended boundary conditions.

[0006] According to aspect (1), a flow reactor is provided. The flow reactor includes: a frame; a plurality of jet modules supported by the frame, each jet module including a metal reaction layer having opposing major outer surfaces, fluid passages disposed within the metal reaction layer, and a plurality of module ports extending between the major outer surfaces of the metal reaction layer, the module ports including intersection ports that intersect the fluid passages; at least two metal plates, the jet modules being arranged one by one in a first direction generally perpendicular to the major outer surfaces between the at least two metal plates, the at least two metal plates being supported by the frame, wherein each metal plate has a plurality of plate ports; a plurality of metal inserts, each metal insert configured to abut a corresponding pair of ports spaced apart adjacent to each other in the first direction and including at least one intersection port such that each intersection port is abutted by at least one metal insert; and at least two tightening members extending in the first direction through the at least two metal plates and the jet modules, the at least two tightening members being configured to compress the at least two metal plates and the jet modules against the metal inserts.

[0007] According to aspect (2), there is provided a flow reactor according to aspect (1), wherein at least two metal plates include a first metal plate fixed to a frame and a second metal plate supported by the frame, and a jet module is disposed between the first metal plate and the second metal plate.

[0008] According to aspect (3), there is provided a flow reactor according to any one of the foregoing aspects, wherein when viewed in a first direction, the module ports of each jet module are positioned between at least two tightening members.

[0009] According to aspect (4), there is provided a flow reactor according to any one of the foregoing aspects, wherein at least two tightening members are symmetrically positioned with respect to the module port of each jet module.

[0010] According to aspect (5), there is provided a flow reactor according to any one of the foregoing aspects, wherein the module ports of each jet module are aligned along a common line oriented generally perpendicular to the first direction.

[0011] According to aspect (6), there is provided a flow reactor according to aspect (5), wherein at least two tightening members are aligned along the common line.

[0012] According to aspect (7), there is provided a flow reactor according to aspect (5) or aspect (6), wherein the metal reaction layer of each jet module has a plurality of edges extending between its major outer surfaces, and the module port of each jet module is positioned closer to one of the edges.

[0013] According to aspect (8), there is provided a flow reactor according to aspect (7), wherein the common line is oriented generally parallel to one of the edges.

[0014] According to aspect (9), there is provided a flow reactor according to any one of the foregoing aspects, wherein each tightening member is elongated in the first direction.

[0015] According to aspect (10), there is provided a flow reactor according to any one of the foregoing aspects, wherein each tightening member has at least two contact portions configured to abut corresponding outer surfaces of at least two metal plates.

[0016] According to aspect (11), there is provided a flow reactor according to aspect (10), wherein at least one contact portion of each tightening member is configured to adjust the distance along the tightening member between at least two contact portions.

[0017] According to aspect (12), there is provided a flow reactor according to aspect (11), wherein each tightening member is configured as a threaded rod, and at least one contact portion of each tightening member is configured as a threaded nut engaging the threaded rod.

[0018] According to aspect (13), there is provided a flow reactor according to aspect (12), wherein each contact portion of each tightening member is configured to engage a threaded nut of a threaded rod.

[0019] According to aspect (14), there is provided a flow reactor according to any one of the preceding aspects, wherein each metal insert includes a first body portion that is monolithic and extends between opposite end faces of the metal insert along a central axis that is generally parallel to a first direction.

[0020] According to aspect (15), there is provided a flow reactor according to aspect (14), wherein the first body portion is elongated in the first direction.

[0021] According to aspect (16), there is provided a flow reactor according to aspect (14) or aspect (15), wherein when viewed in a cross-section generally perpendicular to the first direction, the first body portion has a cylindrical shape.

[0022] According to aspect (17), there is provided a flow reactor according to any one of aspects (14) to (16), wherein each end face of each metal insert has a surface portion that is generally perpendicular to the first direction.

[0023] According to aspect (18), there is provided a flow reactor according to aspect (17), wherein each surface portion of each metal insert is configured to abut one or more of a major outer surface proximate each module port and a plate surface proximate each plate port.

[0024] According to aspect (19), there is provided a flow reactor according to any one of aspects (14) to (18), wherein each end face of each metal insert has a protrusion extending therefrom, the protrusion being configured to be received in a corresponding pair of ports adjacent to the metal insert.

[0025] According to aspect (20), there is provided a flow reactor according to aspect (19), wherein the protrusions of each metal insert are arranged concentrically with respect to the central axis of the first body portion.

[0026] According to aspect (21), there is provided a flow reactor according to any one of the preceding aspects, wherein the metal insert includes a first insert configured to interchangeably abut corresponding pairs of ports, each first insert being configured to provide a first flow condition in which the ports in the corresponding pairs of ports are connected to each other in a jet-like manner.

[0027] According to aspect (22), there is provided a flow reactor according to any one of the preceding aspects, wherein the metal insert includes a second insert configured to interchangeably abut corresponding pairs of ports, each second insert being configured to provide a second flow condition in which the ports in the corresponding pairs of ports are isolated from each other in a jet manner.

[0028] According to aspect (23), there is provided a flow reactor according to any one of the preceding aspects, wherein the metal insert includes a third insert configured to interchangeably abut corresponding pairs of ports, each third insert being configured to provide a third flow condition in which the ports in the corresponding pairs of ports are connected to each other in a jet manner and connected to the first port.

[0029] According to aspect (24), there is provided a flow reactor according to any one of the preceding aspects, wherein the metal insert includes a fourth insert configured to interchangeably abut corresponding pairs of ports, each fourth insert being configured to provide a fourth flow condition in which (i) the ports in the corresponding pairs of ports are isolated from each other in a jet manner and (ii) one of the ports in the corresponding pairs of ports is connected to the second port in a jet manner.

[0030] According to aspect (25), there is provided a flow reactor according to any one of the preceding aspects, wherein the metal reaction layer, at least two metal plates, the metal insert, and parts of at least two tightening members of each jet module are formed of the same metal.

[0031] According to aspect (26), there is provided a flow reactor according to aspect (25), wherein the same metal includes one of stainless steel, titanium, and tantalum.

[0032] According to aspect (27), there is provided a flow reactor according to aspect (25) or aspect (26), wherein one or more of the jet modules include a heat exchanger, each heat exchanger including two heat exchange layers, the two heat exchange layers being respectively attached to the main outer surface of the metal reaction layer of each of one or more jet modules to define a heat exchange fluid passage therebetween.

[0033] According to aspect (28), there is provided a flow reactor according to aspect (27), wherein each heat exchange layer has a recessed portion defining an exposed portion of the main outer surface that is not covered by the heat exchange layer, and the module ports of each of one or more jet modules are disposed within the exposed portion.

[0034] According to aspect (29), there is provided a flow reactor according to aspect (27) or aspect (28), wherein at least one pair of adjacent jet modules includes a heat exchanger, and the metal insert is disposed between the at least one pair of adjacent jet modules and configured to provide a minimum gap between the heat exchangers in a first direction.

[0035] According to aspect (30), there is provided a flow reactor according to aspect (29), wherein the minimum void is at least 1 mm.

[0036] According to aspect (31), there is provided a flow reactor according to any one of aspects (27) to (30), wherein the two heat exchange layers of each heat exchanger are respectively sealed to the main outer surface of the metal reaction layer of each of one or more jet modules.

[0037] According to aspect (32), there is provided a flow reactor according to any one of aspects (27) to (30), wherein the two heat exchange layers of each heat exchanger are respectively fastened to the main outer surface of the metal reaction layer of each of one or more jet modules.

[0038] According to aspect (33), there is provided a flow reactor according to aspect (32), wherein the two heat exchange layers of each heat exchanger are formed of a first metal different from the same metal.

[0039] According to aspect (34), there is provided a flow reactor according to any one of the foregoing aspects, wherein the module port of each jet module includes three module ports.

[0040] According to aspect (35), there is provided a flow reactor according to any one of the foregoing aspects, wherein the module port includes a non-intersecting port that does not intersect the fluid passage, and wherein the corresponding pair of ports adjacent to each metal insert includes: (i) two intersecting ports; (ii) one intersecting port and one non-intersecting port; or (iii) one intersecting port and one plate port. Description of the Drawings

[0041] Figure 1 A side plan view of a metal flow reactor according to an embodiment, the metal flow reactor having metal jet modules stacked between metal plates and supported by a frame;

[0042] Figure 2 For an embodiment according to Figure 1 A side plan view of one of the metal jet modules of the metal flow reactor;

[0043] Figure 3A And Figure 3B For Figure 2 A front plan view of different variants of the metal jet module;

[0044] Figure 4 For an embodiment according to Figure 1 A side plan view of one of the metal plates of the metal flow reactor; and

[0045] Figure 5 ForFigure 4 Front plan view of a metal plate;

[0046] Figure 6 Is a schematic diagram of a metal flow reactor according to a process and instrumentation diagram (P&ID), wherein the arrangement of the metal jet module is compressed against the arrangement of the metal insert, thereby defining the process fluid flow through the reactor;

[0047] Figure 7 Is according to an embodiment Figure 6 Simplified schematic diagram of a metal flow reactor, wherein heat exchangers are omitted from some of the metal jet modules;

[0048] Figure 8 Is according to another P&ID Figure 6 Simplified schematic diagram of a metal flow reactor, wherein another arrangement of the metal jet module is compressed against another arrangement of the metal insert, thereby defining the process fluid flow through the reactor;

[0049] Figures 9 to 19 Is Figure 6 And Figure 8 Views of different variants of the metal insert;

[0050] Figure 20 And Figure 21 Is a cross-sectional view of the metal support of the metal flow reactor along line A-A through Figure 7 ; and

[0051] Figure 22 Is a schematic diagram of a metal flow reactor having a metal jet module having a heat exchanger configured to provide at least two different heating zones. Detailed Description

[0052] For the purpose of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It should be understood that no limitation of the scope of the present disclosure is thereby intended. Further, it should be understood that the present disclosure includes any changes and modifications to the illustrated embodiments, and includes other applications of the principles disclosed herein, as would typically occur to one of ordinary skill in the art to which the present disclosure pertains.

[0053] As used herein, when used in a list of two or more items, the term "and / or" means that any one of the listed items may be employed alone, or any combination of two or more of the listed items may be employed. For example, if a composition is described as containing components A, B, and / or C, then the composition may contain only A; only B; only C; a combination of A and B; a combination of A and C; a combination of B and C; or a combination of A, B, and C.

[0054] In this document, relational terms such as first and second, top and bottom, etc. are used only to distinguish one entity or action from another entity or action, and do not necessarily require or imply any actual such relationship or order between such entities or actions.

[0055] As used herein, the term "about" means that a quantity, size, formulation, parameter, and other quantities and characteristics are not and need not be exact, but may be approximate and / or larger or smaller as desired, thereby reflecting tolerances, conversion factors, rounding, measurement errors, etc., and other factors known to those skilled in the art. When the term "about" is used to describe a value or endpoint of a range, the present disclosure should be understood to include the recited specific value or endpoint. Whether or not the numerical values or endpoints of the ranges in this specification are recited with "about", the numerical values or endpoints of the ranges are intended to include two embodiments: one modified by "about" and one not modified by "about". It should be further understood that each endpoint of a range is meaningful not only in relation to the other endpoint, but also independently of the other endpoint.

[0056] Unless defined elsewhere in connection with a specific term or phrase, the terms "substantially", "substantially" and their variants as used herein are intended to mean that the described feature is equal to or approximately equal to a value or description. For example, a "substantially planar" surface is intended to mean a surface that is planar or approximately planar. Additionally, "substantially" is intended to mean that two values are equal or approximately equal. In some embodiments, "substantially" may mean within about 10% of each other, such as within about 5% of each other or within about 2% of each other.

[0057] As used herein, directional terms such as up, down, right, left, front, back, top, bottom, above, below, etc. are made only with reference to the drawings and are not intended to imply absolute orientation.

[0058] As used herein, unless expressly stated to the contrary, the terms "the", "a" or "an" mean "at least one" and shall not be limited to "only one". Thus, for example, references to "a component" include embodiments having two or more such components unless the context clearly dictates otherwise.

[0059] Figure 1Side plan view of a metal flow reactor 100 according to an embodiment, the metal flow reactor comprising a frame 104, a plurality of metal jet modules 108, at least two metal plates 112, a plurality of metal inserts 116, and at least two tightening members 120. The frame 104 includes a first support member 124 that defines a first support surface 126 on an upper side of the first support member 124. The frame 104 further includes at least one second support member 128 that extends laterally (e.g., substantially perpendicular) from one end of the first support member 124. In an embodiment, the frame 104 includes two second support members 128 that extend from opposite ends of the first support member 124, respectively.

[0060] The frame 104 is configured to support the various components of the metal flow reactor 100. In an embodiment, the frame 104 is formed of metal. The metal of the frame 104 can be any metal having sufficient strength and durability to support the weight of the various other components of the flow reactor 100 during operation and transportation of the flow reactor 100. In an embodiment, the frame 104 is formed of stainless steel. In an embodiment, the frame 104 rigidly supports or secures (e.g., via fasteners, adhesives, and / or similar mechanical fixation) the components of the metal flow reactor 100 such that there is generally no relative movement between the frame 104 and the rigidly supported or secured components. In an embodiment, the frame 104 slidably supports the components of the metal flow reactor 100 such that relative movement between the frame 104 and the slidably supported components is permitted, for example, in a first direction (e.g., the z-direction) or in multiple directions (e.g., any direction along the plane defined by the first support surface 126). The frame 104 can define a portion (e.g., a base or bottom portion 130) of an enclosure configured to surround the components of the metal flow reactor 100. In an embodiment, the frame 104 includes a plurality of rollers or wheels 132 that enable the metal flow reactor 100 to be portable.

[0061] Now in conjunction with Figure 1 Reference Figure 2 、 Figure 3A And Figure 3B , aspects of the metal jet module 108 are shown. Figure 2 Is a side plan view of one of the jet modules 108 of the Figure 1 metal flow reactor 100 according to an embodiment. Figure 3A And Figure 3B Is Figure 2Front plan view of different variants of the metal jet module. The jet module 108 is supported by the frame 104. In an embodiment, the jet module 108 is slidably supported on the frame 104, for example, by a first support surface 126 of a first support member 124. The first support surface 126 may permit slidable contact with an edge of the jet module 108 to allow relative movement between the jet module 108 and a portion of the frame 104. In an exemplary embodiment, the jet module 108 is slidably supported on the frame 104 during assembly / dismantling of the metal flow reactor 100. In an embodiment, the jet module 108 may be supported by other portions of the frame 104 (such as a second support member 128) such that the jet module 108 may not contact or only partially contact the first support surface 126 of the first support member 124.

[0062] In an embodiment, each jet module 108 includes a metal reaction layer 134 having opposing (e.g., facing) major outer surfaces 136 and fluid passages 138 disposed within the metal reaction layer 134. The metal reaction layer 134 of each jet module 108 includes two metal layers 140 positioned against each other (e.g., to form a metal bilayer), where each metal layer 140 defines one of the major outer surfaces 136 of the metal reaction layer 134. In an embodiment, the wall of the fluid passage 138 may be entirely defined by only one of the two metal layers 140, or the wall of the fluid passage 138 may be partially defined by the two metal layers 140. In an embodiment, the two metal layers 140 of each metal reaction layer 134 are sealed to each other (e.g., using metal bonding or joining techniques), fastened (e.g., using mechanical fasteners), or a combination thereof, to seal the fluid passage 138 and enable the metal reaction layer 134 to withstand a maximum operating pressure (e.g., 50 bar or higher) during operation of the metal flow reactor 100. In an exemplary embodiment, the two metal layers 140 of each metal reaction layer 134 are sealed to each other. Although the metal reaction layer 134 is described as including two metal layers positioned against each other, other embodiments of the metal reaction layer may be contemplated. For example, in an embodiment, the metal reaction layer and the fluid passages disposed therein may be formed via three-dimensional (3D) printing techniques using metal powder.

[0063] Each jet module 108 further includes a plurality of module ports 142 extending between the major outer surfaces 136 of the metal reaction layer 134. In an exemplary embodiment, each jet module 108 includes three module ports 142, as Figure 2 , Figure 3A and Figure 3BAs shown. In an embodiment, each jet module 108 may include more or fewer than three module ports, for example, two module ports, four module ports, or five module ports. In an embodiment, some of the jet modules may have a different number of module ports than other jet modules in the same metal flow reactor 100.

[0064] As Figure 3A and Figure 3B shown, the module ports 142 of each jet module 108 are aligned along a common line 144. In an embodiment, the common line 144 is oriented generally perpendicular to a first direction (e.g., the z-direction), for example, generally parallel to the major outer surface 136 of the jet module 108. In an embodiment, the metal reaction layer 134 of each jet module 108 has a plurality of edges 146 extending between its major outer surfaces 136. In an embodiment, the module ports 142 of each jet module 108 are positioned closer to one of the edges 146. In an embodiment, the common line 144 is generally parallel to one of the edges.

[0065] Referring again to 1 Figure 2 、 Figure 3A and Figure 3B , the module ports 142 of each jet module 108 are positioned to be spaced apart from each other from the top side to the bottom side of the metal flow reactor 100. The module ports 142 may be described with reference to their sequential positions (along the common line 144) from the top side to the bottom side. For example, the module port closest to the top side may be the first module port 142A, the next module port (along the common line 144) adjacent to the first module port 142A may be the second module port 142B, and so on, such that Figure 2 、 Figure 3A and Figure 3B each of the jet modules 108 depicted in includes a first module port 142A, a second module port 142B, and a third module port 142C. As mentioned, in an embodiment, the jet module 108 may include more or fewer than three module ports 142.

[0066] As Figure 3A and Figure 3B shown, the module ports 142 include intersection ports that intersect the fluid passage 138 and (optional) non-intersection ports that do not intersect the fluid passage 138. The module ports 142 configured as intersection ports may be followed by the subscript "I" (e.g., 142A I 、142B I 、142C Idesignated by, for example, 142A, 142B, 142C, etc. The module port 142 configured as a non-intersecting port can be followed by the sequential position of the module port (e.g., 142A, 142B, 142C, etc.) and then the subscript "N" (e.g., 142A N , 142B N , 142C N etc.). Although the non-intersecting port is described as corresponding to the module port 142 that extends through the metal reaction layer 134 but does not intersect the fluid passage 138, in some embodiments, it is contemplated that the non-intersecting port may include other non-functional ports, such as a recess in one of the major outer surfaces 136 of the metal reaction layer 134.

[0067] In an embodiment, the jet module 108 may include two or more module variants that differ in the number of module ports 142, the number of intersecting ports, and / or the number of non-intersecting ports. In an exemplary embodiment, the jet module includes a first module variant 108'( Figure 3A ) and a second module variant 108''( Figure 3B ), each of which has three module ports 142A, 142B, 142C. As Figure 3A shown, the three module ports 142A, 142B, 142C of the first module variant 108' can be configured as three intersecting ports. For example, the first module port 142A of the first module variant 108' can be configured as an intersecting port that intersects the outlet end of the fluid passage 138 (e.g., the first intersecting port 142A I ). The second module port 142B of the first module variant 108' can be configured as an intersecting port that intersects the inlet end of the fluid passage 138 (e.g., the second intersecting port 142B I ). The third module port 142C of the first module variant 108' can be configured as an intersecting port that intersects the inlet end of the fluid passage 138 (e.g., the third intersecting port 142C I ).

[0068] As Figure 3B shown, the three module ports 142A, 142B, 142C of the second module variant 108'' can be configured as two intersecting ports and one non-intersecting port. For example, the first module port 142A of the second module variant 108'' can be configured as an intersecting port that intersects the outlet end of the fluid passage 138 (e.g., the first intersecting port 142A I ). The second module port 142B of the second module variant 108'' can be configured as a non-intersecting port that does not intersect the fluid passage 138 (e.g., the second non-intersecting port 142B N)。The third module port 142C of the second module variant 108 can be configured as an intersecting port (e.g., the third intersecting port 142C) that intersects the inlet end of the fluid passage 138 I )。It should be understood that the second module port 142B can be configured as the second intersecting port 142B depending on the module variant I ( Figure 3A ) or the second non-intersecting port 142B N ( Figure 3B )。It should be further understood that the jet module 108 can include other module variants that differ in the number of module ports 142, the number of intersecting ports, and / or the number of non-intersecting ports.

[0069] Now, with reference to Figure 1 and Figure 4 and Figure 5 , aspects of at least two metal plates 112 are shown. As shown in Figure 1 , the at least two metal plates 112 are supported by the frame 104. The jet modules 108 are arranged one by one (e.g., sequentially) between the at least two metal plates 112 in a first direction (e.g., the z-direction), which is generally perpendicular to the main outer surface 136 of the jet modules 108. In an embodiment, the at least two metal plates 112 include a first metal plate 112A fixed to the frame 104 and a second metal plate 112B supported by the frame 104. In an embodiment, the first metal plate 112A can be fixed (e.g., rigidly fixed) to the second support member 128 of the frame 104 by any fastening technique (e.g., mechanical fasteners, metal bonding / jointing techniques, performance adhesives, etc.). As shown in Figure 1 and Figure 5 , the first metal plate 112A can include mounting holes 148, and the second support member 128 can include mounting holes through which mechanical fasteners can be positioned and fixed to fix the first metal plate 112A to the second support member 128 of the frame 104. As shown in Figure 1 , the jet modules 108 are arranged (e.g., sequentially) between the first metal plate 112A and the second metal plate 112B.

[0070] Each of the first metal plate 112A and the second metal plate 112B includes a plurality of plate ports 150 that extend between opposite main plate surfaces 152 of each metal plate. In an embodiment, the number and position of the plate ports 150 of each of the first metal plate 112A and the second metal plate 112B can correspond to the module ports 142 of each of the jet modules 108 (e.g., adjacent jet modules). For example, when each of the jet modules 108 includes three module ports 142, as shown in Figure 2 , Figure 3A and Figure 3BAs shown, each of the first metal plate 112A and the second metal plate 112B may include three plate ports 150 respectively positioned to correspond to the three module ports 142. In other words, between either the first metal plate 112A or the second metal plate 112B and the adjacent jet module 108, each metal plate has a first plate port 150A corresponding to the first module port 142A of the adjacent jet module, a second plate port 150B corresponding to the second module port 142B of the adjacent jet module, and a third plate port 150C corresponding to the third module port 142C of the adjacent jet module. The plate ports 150 may be aligned along a common line 154, which is oriented in the same direction as the common line 144 of the module ports 144 of each jet module 108. In an embodiment, each of the plate ports 150 shares a common axis with the corresponding module port 142 while being spaced apart from the corresponding module port 142 along a first direction, such that the plate port 150 and the module port 142 form corresponding pairs of ports that are adjacent and spaced apart from each other in the first direction.

[0071] Now in connection with Figure 1 Referring to Figure 6 , other aspects of the jet module 108, the metal insert 116, and at least two tightening members 120 are shown. Figure 6 Schematic diagram of a metal flow reactor (e.g., Figure 1 the metal flow reactor 100) according to a first process and instrumentation diagram (P&ID), in which the jet module 108 is compressed against a first arrangement of the metal insert 116 to define a process fluid flow through the metal flow reactor 100. For ease of description, a non-limiting naming convention is provided for referring to the different jet modules 108 associated with the metal flow reactor 100.

[0072] As observed in Figure 6 , the left side of the metal flow reactor 100 may be regarded as the inlet side (e.g., two or more reactant materials may be introduced at the inlet side), and the right side of the metal flow reactor 100 may be regarded as the outlet side (e.g., one or more product materials may be obtained from the outlet side). It should be understood that in an embodiment, the inlet side and the outlet side may be reversed. Since the jet modules 108 are arranged one by one in a first direction (e.g., the z direction) between the first metal plate 112A and the second metal plate 112B, the jet modules 108 may be identified by their sequential positions from the inlet side to the outlet side. For example, the jet module closest to the inlet side and adjacent to the first metal plate 112A may be the first jet module 108A, the next jet module adjacent to the first jet module 108A in the first direction may be the second jet module 108B, and so on, such that Figure 6The jet module depicted therein includes a first jet module 108A, a second jet module 108B, a third jet module 108C, and a fourth jet module 108D. Additionally, for the naming convention, the jet module 108 is oriented such that one side of each jet module 108 is an inlet side 162 facing the inlet side of the metal flow reactor 100 ( Figure 2 ), and the opposite side of each jet module 108 is an outlet side 164 facing the outlet side of the metal flow reactor 100 ( Figure 2 ).

[0073] Still referring to Figure 6 , each metal insert 116 (any variant A, B, etc.) is configured to abut a corresponding pair of ports that are spaced apart adjacent to each other in a first direction (e.g., the z-direction). For simplicity, only the corresponding pair of ports is described with respect to the second plate port 150B and the second module port 142B (e.g., configured as intersecting ports or non-intersecting ports). As described later in this disclosure, the corresponding pair of ports may also include the first plate port 150A, the first module port 142A (e.g., configured as intersecting ports or non-intersecting ports), the third plate port 150C, and the third module port 142C (e.g., configured as intersecting ports or non-intersecting ports). The corresponding pair of ports abutted by each metal insert 116 may include: (i) two intersecting ports (e.g., the second intersecting port 142B of the first jet module 108A′ I and the second intersecting port 142B of the second jet module 108B′ I ); (ii) one intersecting port and one non-intersecting port (e.g., the second intersecting port 142B of the second jet module 108B′ I and the second non-intersecting port 142B of the third jet module 108C″ N ); or (iii) one intersecting port and one plate port (e.g., the second intersecting port 142B of the first jet module 108A′ I and the second plate port 150B of the first metal plate 112A), such that each intersecting port of the metal flow reactor 100 is abutted by at least one metal insert 116.

[0074] In an embodiment, the corresponding pair of ports abutted by each metal insert 116 may optionally include: (i) two non-intersecting ports (e.g., the second non-intersecting port 142B of the third jet module 108C″ N and the second non-intersecting port 142B of the fourth jet module 108D″ N ); or (ii) one non-intersecting port and one plate port (e.g., the second non-intersecting port 142B of the fourth jet module 108D″ Nand the second plate port 150B of the second metal plate 112B). The metal insert 116 includes different variants that are interchangeable within the metal flow reactor 100 and configured to enable different flow conditions between corresponding pairs of ports. Different variants are described later in this disclosure with reference to Figures 9 to 19 Describe different variants.

[0075] Still in conjunction with Figure 1 Reference 6, at least two tightening members 120 are configured to compress at least two metal plates 112 (e.g., the first metal plate 112A and the second metal plate 112B) and the jet module 108 (e.g., the first jet module 108A, the second jet module 108B, the third jet module 108C, and the fourth jet module 108D) against the metal insert 116 (any variant A, B, etc.). The at least two tightening members 120 extend in a first direction (e.g., the z-direction) through the at least two metal plates 112 and the jet module 108. For example, the first metal plate 112A and the second metal plate 112B may each include perforations 168 ( Figure 4 and Figure 5 ), and the perforations are configured with gaps to allow the at least two tightening members 120 to pass therethrough. Similarly, the jet module 108 may each include perforations 170 ( Figure 2 , Figure 3A and Figure 3B ), and the perforations are configured with gaps to allow the at least two tightening members 120 to pass therethrough.

[0076] As Figure 6 shown, each tightening member 120 is elongated in a first direction (e.g., the z-direction) and includes at least two contact portions 172 positioned at its opposite ends. The at least two contact portions 172 are configured to abut the respective outer surfaces of the at least two metal plates 112. In an embodiment, at least one contact portion 172 of each tightening member 120 is configured to adjust the distance D along the tightening member 120 in the first direction (e.g., the z-direction) between the at least two contact portions 172. For example, one contact portion 172 is configured to decrease and / or increase the distance D between the two contact portions 172 via its actuation to respectively increase and / or decrease the compression of the at least two metal plates 112 and the jet module 108 against the metal insert 116. In an exemplary embodiment, each tightening member 120 is configured as a threaded rod, and at least one contact portion 172 of each tightening member 120 is configured as a threaded nut that engages the corresponding threaded rod. In an embodiment, each contact portion 172 of each tightening member 120 is configured as a threaded nut that engages the threaded rod.

[0077] In an embodiment where at least two tightening members 120 are configured as two threaded rods with corresponding threaded nuts, the threaded rods 120 can be configured to have a predetermined parallelism relative to each other. For example, the threaded rod 120 closest to the top side of the metal flow reactor 100 can have a top distance D between its corresponding threaded nuts 172 top , and the threaded rod closest to the bottom side of the metal flow reactor 100 can have a bottom distance D between its corresponding threaded nuts 172 bottom . The predetermined parallelism can be defined by the following equation:

[0078] |D top –D bottom |< 0.2 mm

[0079] In an embodiment, the threaded nuts 172 are configured to be tightened to a predetermined torque. In an embodiment, the predetermined torque is related to the total number of jet modules 108 in the metal flow reactor 100. For example, the predetermined torque can be about 0.75 N·m to about 1.25 N·m per jet module 108. The predetermined torque of an exemplary metal flow reactor including five jet modules 108 can be in the range of about 3.75 N·m (e.g., 0.75 × 5) to about 6.25 N·m (e.g., 1.25 × 5). The predetermined torque of an exemplary metal flow reactor including four jet modules 108 can be in the range of about 3.00 N·m (e.g., 0.75 × 4) to about 5.00 N·m (e.g., 1.25 × 4). In an embodiment, the predetermined torque range per jet module can be greater than or less than about 0.75 N·m to about 1.25 N·m per jet module. In an embodiment, the threaded rods 120 have a predetermined parallelism, and the threaded nuts 172 have a predetermined torque.

[0080] Reference Figure 2 、 Figure 3A 、 Figure 3B and Figure 6 , at least two tightening members 120 are positioned relative to the module port 142 so as to contain working pressure in the jet flow path of the jet module 108. For example, when viewed in a first direction (e.g., the z - direction), the module port 142 of each jet module 108 is positioned between at least two tightening members 120. In an embodiment, at least two tightening members 120 are symmetrically positioned with respect to the module port 142 of each jet module 108. For example, as shown in Figure 3A and Figure 3B , at least two tightening members 120 (e.g., whose positions are indicated by the perforations 170) can be symmetrically positioned with respect to a symmetry line 174 that bisects the module port 142. In an embodiment, at least two tightening members 120 are aligned along a common line 144, and the module ports 142 are aligned along the common line.

[0081] Still referring to Figure 2 、 Figure 3A 、 Figure 3B and Figure 6 , one or more of the jet modules 108 may include a heat exchanger 178. Each heat exchanger 178 includes two heat exchange layers 180 ( Figure 2 ), the two heat exchange layers being attached respectively to the major outer surface 136 of the metal reaction layer 134 of each of one or more jet modules 108 to define a heat exchange fluid passage 182 therebetween ( Figure 3A and Figure 3B ). The heat exchange fluid passage 182 is configured to bring the heat exchange fluid into contact with the major outer surface 136 of the jet module 108 and to convey the heat exchange fluid along a path that generally coincides with the fluid passage within the metal reaction layer 134 of each jet module 108.

[0082] As best shown in Figure 2 、 Figure 3A and Figure 3B , each heat exchange layer 180 has a recessed portion 184 that defines an exposed portion 186 of the major outer surface 136 that is not covered by the heat exchange layer 180. The module port 142 of each of one or more jet modules 108 is disposed within the exposed portion 186 such that the metal insert 116 is in direct adjacency to the module port 142 and the portion of the major outer surface 136 that surrounds the module port 142. As best shown in Figure 2 , the perforations 170 extend completely through the heat exchange layer 180 such that at least two fastening members 120 can pass freely through each heat exchanger 178. The perforations 170 and the exposed portion 186 enable the heat exchanger 178 to be decoupled from the compression applied to the jet module 108, the at least two metal plates 112, and the metal insert 116 via the at least two fastening members 120. This configuration may allow for relaxation of the mechanical tolerances of the heat exchanger 178 and limit the effects of its expansion and / or contraction with temperature variations during operation of the metal flow reactor 100.

[0083] In an embodiment, at least one pair of adjacent jet modules 108 may include a heat exchanger 178 (e.g., Figure 6The first jet module 108A' and the second jet module 108B' shown therein). A metal insert 116 disposed between at least a pair of adjacent jet modules 108 can be configured to provide a minimum gap between heat exchangers 178 in a first direction (e.g., the z direction). In an exemplary embodiment, the minimum gap is at least 1 mm. In an embodiment, two heat exchange layers 180 of each heat exchanger 178 are respectively sealed to the major outer surface 136 of the metal reaction layer 134 of each of one or more jet modules 108. In such an embodiment, the heat exchange layers 180 can be sealed via the same metal bonding or joining technique used to join the two metal layers 140 of each metal reaction layer 134.

[0084] In an embodiment, two heat exchange layers 180 of each heat exchanger 178 can be respectively fastened to the major outer surface 136 of the metal reaction layer 134 of each of one or more jet modules 108. For example, as Figure 3A and Figure 3B shown, each heat exchange layer 180 includes a plurality of mounting holes 188 disposed around the perimeter of the heat exchange layer 180. The metal reaction layer 134 can include mounting holes (not shown) corresponding to the mounting holes 188 of the heat exchange layer 180 such that the heat exchange layer 180 can be attached to the metal reaction layer 134 using mechanical fasteners (not shown). In an embodiment, washers (not shown) can be positioned between the heat exchange layer 180 and the metal reaction layer 134 to improve the seal and heat transfer therebetween.

[0085] To account for potential different thermal expansions / contractions between different components of the metal flow reactor 100 and reduce the likelihood of leakage (e.g., at the joints between adjacent jet modules 108), the metal reaction layer 134 of each jet module 108, at least two metal plates 112, the metal insert 116, and portions (e.g., the elongate portions) of at least two tightening members 120 are formed of the same metal. In an embodiment, the same metal includes stainless steel, One of titanium and tantalum. For metal categories that include various grades and / or compositions within the same category (e.g., stainless steel includes 303SS, 304SS, etc.), it should be understood that the term "same metal" can also refer to the same grade and / or the same composition of the indicated metal category or type. For example, if the same metal is stainless steel, then all of the mentioned components formed of the same metal will be formed of 303SS, or all of the mentioned components formed of the same metal will be formed of 304SS. In an embodiment, the contact portions 172 of at least two tightening members 120 can be formed of a material different from the same metal. In such a configuration, when the temperature of the metal flow reactor 100 rises or falls within the operating limits, different components that affect the likelihood of leakage are configured to have similar or substantially the same expansion or contraction along the first direction, such that no voids occur along the metal flow reactor 100. Such a configuration enables the metal flow reactor 100 according to the present disclosure to operate at a working pressure of up to 50 bar or higher and within a temperature range of approximately -60°C to greater than 200°C without leaking beyond a predetermined value.

[0086] In an embodiment where the heat exchange layer 180 of each heat exchanger 178 is fastened to the metal reaction layer 134, the heat exchange layer 180 can be formed of a first metal that is different from the same metal forming the metal reaction layer 134, at least two metal plates 112, the metal inserts 116, and portions of at least two tightening members 120. In such an embodiment, the first metal can be aluminum, which has a lower cost than the same metal.

[0087] Now referring Figure 7 , the metal flow reactor 100 is shown with another arrangement of the heat exchanger 178. Figure 7 For the Figure 6 metal flow reactor 100 according to an embodiment, which is a simplified schematic diagram, where the heat exchanger 178 is omitted from some of the jet modules 108. Figure 7 Relative to Figure 6 simplified because, for clarity, the frame 104 and at least two tightening members 120 are omitted from the Figure 7 view, and the module ports 142 and the plate ports 150 are not labeled in Figure 7 . Specifically, as shown in Figure 7 , the first jet module 108A' and the third jet module 108C" include the heat exchanger 178, while the second jet module 108B' and the fourth jet module 108D" do not include the heat exchanger 178. Such modularity of the heat exchanger 178 enables complex customization of the hot zones within the metal flow reactor 100.

[0088] Figure 7Also shown is the metal flow reactor 100 with the optional metal inserts removed. As described above, each pair of ports adjacent to a respective metal insert 116 may optionally include (i) two non-intersecting ports or (ii) one non-intersecting port and one plate port. Figure 6 The metal flow reactor 100 of Figure 6 includes these optional metal inserts 116. For example, N the metal flow reactor 100 of N includes: (i) an optional metal insert 116 between the second non-intersecting port 142B of the third jet module 108C″ N and the second non-intersecting port 142B of the fourth jet module 108D″; and (ii) an optional metal insert 116 between the second non-intersecting port 142B of the fourth jet module 108D″ Figure 7 and the second plate port 150B of the second metal plate 112B. In contrast,

[0089] Figure 8 is not included with these optional metal inserts 116 at the mentioned pairs of corresponding ports. The omission of such optional metal inserts can save costs and simplify the assembly / dismantling of the metal flow reactor 100.

[0089] Figure 8 For Figure 6 is a simplified schematic view of the metal flow reactor 100 according to a second P&ID different from the first P&ID, in which the jet modules 108 are compressed against a second arrangement of the metal inserts 116 different from the first arrangement of the metal inserts 116 so as to define the process fluid flow through the reactor. Figure 8 is simplified relative to Figure 6 because, for clarity, the frame 104 and at least two tightening components 120 are omitted from the Figure 8 view. As described above, the metal inserts 116 include different variants that are interchangeable within the metal flow reactor 100 and configured to enable different flow conditions between corresponding pairs of ports. By combining different variants in different arrangements, a first arrangement of the metal inserts 116 ( Figure 6 and Figure 7 ), a second arrangement of the metal inserts 116 ( Figure 8 ), and any other arrangement of the metal inserts 116 are formed.

[0090] Figures 9 to 19 Further details of the metal inserts 116 are illustrated, including common or substantially similar features among the different variants of the metal inserts 116. As Figures 9 to 19As shown, each metal insert 116 includes a first body portion 202 that is monolithic and extends between opposite end faces 204 of the metal insert along a central axis oriented generally parallel to a first direction (e.g., the z - direction). When viewed in a cross - section oriented generally perpendicular to the first direction, the first body portion 202 is elongated in the first direction and has a cylindrical shape.

[0091] Still referring Figures 9 to 19 , each end face 204 of each metal insert 116 has a protrusion 208 extending therefrom. The protrusion is configured to be received within a corresponding pair of ports (e.g., module port 142 and / or board port 150) adjacent to the metal insert 116. In an embodiment, the protrusion 208 and the ports 142, 150 have corresponding sizes configured to enable a relatively small clearance therebetween, such that the protrusion 208 enables the metal insert 116 to be self - centered within the ports 142, 150. In an embodiment, the clearance or gap between the protrusion 208 and the ports 142, 150 is approximately 0.2 mm, e.g., in the range of about 0.15 mm to about 0.25 mm. In an embodiment, the protrusions 208 of each metal insert 116 are concentrically arranged relative to the central axis 206 of the first body portion 202.

[0092] Still referring Figures 9 to 19 , each end face 204 of each metal insert 116 has a surface portion 210 oriented generally perpendicular to the first direction (e.g., the z - direction). Each surface portion 2010 of each metal insert 116 is configured to abut one or more of the major outer surface 136 adjacent to each module port 142 (e.g., configured as an intersecting port or a non - intersecting port) and the major board surface 152 adjacent to each board port 150. As Figures 9 to 19 shown, each end face 204 of each metal insert 116 has a groove 212 configured to receive a washer or O - ring (not shown). The washer is configured to be compressed between the end face 204 and one or more of the major outer surface 136 adjacent to each module port 142 and the major board surface 152 adjacent to each board port 150, and to surround the ports 142, 150 adjacent to the metal insert 116. As Figures 9 to 19 shown, the grooves 212 of each metal insert 116 are concentrically arranged relative to the central axis 206 of the first body portion 202. In embodiments where the metal insert 116 abuts a board port 150 or a module port 142 configured as a non - intersecting port (e.g., the module port 142 does not intersect the fluid passage 138), the washer or O - ring may be omitted from the corresponding end face 204 of the metal insert 116.

[0093] Figure 9 and Figure 10Depict a metal insert variant, where the metal insert 116 includes a first insert 116A (also referred to as a "through insert") configured to interchangeably abut corresponding pairs of ports. Each first insert 116A is configured to establish a first flow condition in which the ports in a corresponding pair of ports are connected to each other in a jetting manner. As Figure 9 and Figure 10 shown, a first body portion 202 of each first insert 116A defines a first fluid passage 214 that extends through the first insert 116A and connects in a jetting manner the corresponding pair of ports abutted by the first insert 116A. In an embodiment, the first fluid passage 214 is concentrically arranged with respect to a central axis 206 of the first body portion 202.

[0094] Figure 11 and Figure 12 Illustrate another metal insert variant, where the metal insert 116 includes a second insert 116B (also referred to as a "plug insert") configured to interchangeably abut corresponding pairs of ports. Each second insert 116B is configured to establish a second flow condition in which the ports in a corresponding pair of ports are jettedly isolated from each other. As Figure 11 and Figure 12 shown, the first body portion 202 of each second insert 116B is configured to be fluid-impermeable so as to jettingly isolate the corresponding pair of ports abutted by the second insert 116B. For example, the first body portion 202 does not contain any passages, channels, or communicating pores that would enable fluid to traverse between opposite end faces 204 of the second insert 116B.

[0095] Figure 13 Show another metal insert variant, where the metal insert 116 includes a third insert 116C (also referred to as a "sensing through insert") configured to interchangeably abut corresponding pairs of ports. Each third insert 116C is configured to establish a third flow condition in which the ports in a corresponding pair of ports are connected to each other in a jetting manner and are connected to a first port 216. As Figure 13As shown, the first body portion 202 of each third insert 116C defines a second fluid passage 218 that extends through the third insert 116C and jet-connects a corresponding pair of ports that are adjacent to the third insert 116C. Each third insert 116C also has a second body portion 220 that extends laterally from the first body portion 202. The second body portion defines a third fluid passage 222 that jet-connects to the second fluid passage 218 at one end and to the first port 216 at the opposite end. The third insert 116C enables an integrated measurement point along the process fluid flow through the metal flow reactor 100 via a sensor (e.g., pressure, flow rate, temperature, chemical in-line analysis, etc.) connected to the first port 216 of the third insert 116C.

[0096] Figure 14 Another metal insert variant is shown, where the metal insert 116 includes a fourth insert 116D (also referred to as an "intermediate insert") configured to interchangeably abut corresponding pairs of ports. Each fourth insert 116D is configured to provide a fourth flow condition where (i) the ports in a corresponding pair of ports are jet-isolated from each other and (ii) one port in a corresponding pair of ports is jet-connected to the second port 224. As Figure 14 shown, each fourth insert 116D has a third body portion 226 that extends laterally from the first body portion 202. The first body portion 202 and the third body portion 226 define a fourth fluid passage 228 that jet-connects to one port in a corresponding pair of ports and to the second port 224. In an embodiment, the fourth insert 116D enables the addition of an additional fluid to the process fluid flow downstream of the inlet side of the metal flow reactor 100. In such embodiments, the additional fluid can be delivered to the second port 224 via a flexible metal conduit (not shown) to account for expansion / contraction under varying temperature conditions during operation of the metal flow reactor 100 due to stacking of the jet modules.

[0097] In an embodiment, the fourth insert 116D is also capable of enabling the integration of serial sensors. For example, serial sensors can be jet-connected in series to the second ports 224 of two fourth inserts 116D positioned between adjacent jet modules 108. One of the two fourth inserts 116D is positioned upstream of the serial sensor and is jet-connected to the module port 142 to drain the process jet flow from the adjacent upstream jet module. The other of the two fourth inserts 116C is positioned downstream of the serial sensor and is jet-connected to the module port 142 to receive the process fluid flow into the adjacent downstream jet module 108.

[0098] The first insert 116A, the second insert 116B, the third insert 116C, and the fourth insert 116D are each configured to abut a corresponding pair of ports, the ports including (i) two intersecting ports or (ii) one intersecting port and one non - intersecting port. Other variants of the metal insert 116 can be used when the corresponding pair of ports includes at least one plate port, such as when the corresponding pair of ports includes (i) one intersecting port and one plate port or (ii) one non - intersecting port and one plate port.

[0099] Figure 15 and Figure 16 Illustrate another metal insert variant, in which the metal insert 116 includes a fifth insert 116E (also referred to as an "end - through insert") configured to interchangeably abut a corresponding pair of ports including at least one plate port 150. Each fifth insert 116E is configured to set a fifth flow condition in which the ports in a corresponding pair of ports including at least one plate port are connected to each other in a jet - flow manner. As illustrated by comparing Figure 9 and Figure 10 with Figure 15 and Figure 16 The fifth insert 116E is similar to the first insert 116A except for one of the protrusions and one of the grooves. In an embodiment, the protrusions 208 of each fifth insert 116E have different lengths in a first direction. For example, the protrusion 208′ configured to be received in the plate port 150 is longer in the first direction than the protrusion 208 configured to be received in the module port 142 (e.g., an intersecting port or a non - intersecting port). In an embodiment, the end face 204 on the side of the fifth insert 116E adjacent to the longer protrusion 208′ does not have a groove or a gasket. Instead, the end face only has a surface portion. In an embodiment, a flexible metal conduit (not shown) can be used to jet - connect to the longer protrusion 208′ to enable delivery of process fluid flow to / from the metal flow reactor 100. The flexible metal conduit is configured to account for expansion / contraction under varying temperature conditions during operation of the metal flow reactor 100 considering the stacking of jet modules.

[0100] Figures 17 to 19 Illustrate another metal insert variant, in which the metal insert 116 includes a sixth insert 116F (also referred to as an "end - plug insert") configured to interchangeably abut a corresponding pair of ports including at least one plate port. Each sixth insert 116F is configured to set a sixth flow condition in which the ports in a corresponding pair of ports including at least one plate port are isolated from each other in a jet - flow manner. As illustrated by comparing Figure 11 and Figure 12 with Figures 17 to 19For comparison, the sixth insert 116F is similar to the second insert 116B, except for one of the grooves and optionally one of the protrusions. For example, the end face 204 adjacent to the plate port 150 on the side of the sixth insert 116F does not have a groove or a gasket. In an optional embodiment, the end face 204 adjacent to the plate port 150 also does not have a protrusion.

[0101] Referring again to Figure 6 and Figure 8 , the jet module 108 and the metal insert 116 are shown in different arrangements to illustrate the modularity of the metal flow reactor 100 and its corresponding process and instrumentation diagram (P&ID). Figure 6 A metal flow reactor 100 is depicted having a reactor stack that includes a first metal plate 112A, a first jet module 108A' (first module variant), a second jet module 108B' (first module variant), a third jet module 108C'' (second module variant), a fourth jet module 108D'' (second module variant), and a second metal plate 112B. The process fluid flow through the Figure 6 metal flow reactor 100 is depicted by a plurality of arrows that are shown in a thick dashed line type and pass through the metal insert configured to permit the corresponding fluid flow therethrough. Figure 6 The metal flow reactor 100 of

[0102] Still referring to Figure 6 , the metal inserts configured to abut adjacent corresponding pairs of ports spaced apart between the first metal plate 112A and the first jet module 108A' include: (i) a sixth insert 116F (end plug insert) abutting the first plate port 150A and the first intersecting port 142A I ; (ii) a fifth insert 116E (end through insert) abutting the second plate port 150B and the second intersecting port 142B I ; and (iii) a fifth insert 116E (end through insert) abutting the third plate port 150C and the third intersecting port 142C I . The metal inserts configured to abut adjacent corresponding pairs of ports spaced apart between the first jet module 108A' and the second jet module 108B' include: (i) a first insert 116A (through insert) abutting two first intersecting ports 142A I ; (ii) a second insert 116A (through insert) abutting two second intersecting ports 142B Ithe fourth insert 116D (intermediate insert); and (iii) adjacent to two third intersecting ports 142C I the second insert 116B (plug insert).

[0103] Still referring to Figure 6 , the metal inserts configured to be adjacent to corresponding pairs of ports that are proximally spaced between the second jet module 108B' and the third jet module 108C'' include: (i) the second insert 116B (plug insert) adjacent to two first intersecting ports 142A I the second insert 116B (plug insert); (ii) the second insert 116B (plug insert) adjacent to the second intersecting port 142A I and the second non - intersecting port 142B N the second insert 116B (plug insert); and (iii) the first insert 116A (through - insert) adjacent to two third intersecting ports 142C I The metal inserts configured to be adjacent to corresponding pairs of ports that are proximally spaced between the third jet module 108C'' and the fourth jet module 108D'' include: (i) the third insert 116C (sensing through - insert) adjacent to two first intersecting ports 142A I ; (ii) optionally, the second insert 116B (plug insert) adjacent to two second non - intersecting ports 142B N ; and (iii) the second insert 116B (plug insert) adjacent to two third intersecting ports 142C I The metal inserts configured to be adjacent to corresponding pairs of ports that are proximally spaced between the fourth jet module 108D'' and the second metal plate 112B include: (i) the sixth insert 116F (end - plug insert) adjacent to the first intersecting port 142A I and the first plate port 150A; (ii) optionally, the sixth insert 116F (end - plug insert) adjacent to the second non - intersecting port 142B N and the second plate port 150B; and (iii) the fifth insert 116E (end - through - insert) adjacent to the third intersecting port 142C I and the third plate port 150C.

[0104] Figure 8 Depicted is a metal flow reactor 100 having a reactor stack that includes a first metal plate 112A, a first jet module 108A' (first module variant), a second jet module 108B'' (second module variant), a third jet module 108C'' (second module variant), a fourth jet module 108D' (first module variant), and a second metal plate 112B. The flow through is depicted by a plurality of arrows through Figure 8The process fluid flow of the metal flow reactor 100, where the plurality of arrows are shown in thick dashed line type and pass through metal inserts configured to permit the corresponding fluid flows to pass therethrough. Figure 8 The metal flow reactor 100 includes three fluid inlets IN1, IN2, IN3, a serial sensor input SS1, and a fluid outlet OUT shown as being associated with a metal insert 116, and the metal insert provides corresponding functions via the process fluid flow arrows in its vicinity.

[0105] Still referring to Figure 8 , the metal inserts configured to be adjacent to corresponding pairs of ports spaced apart in proximity between the first metal plate 112A and the first jet module 108A' include: (i) a sixth insert 116F (end plug insert) adjacent to the first plate port 150A and the first intersecting port 142A I ; (ii) a fifth insert 116E (end through insert) adjacent to the second plate port 150B and the second intersecting port 142B I ; and (iii) a fifth insert 116E (end through insert) adjacent to the third plate port 150C and the third intersecting port 142C. The metal inserts configured to be adjacent to corresponding pairs of ports spaced apart in proximity between the first jet module 108A' and the second jet module 108B'' include: (i) a first insert 116A (through insert) adjacent to two first intersecting ports 142A I ; (ii) a second insert 116B (plug insert) adjacent to the second intersecting port 142B I and the second non - intersecting port 142B I ; and (iii) a second insert 116B (plug insert) adjacent to two third intersecting ports 142C. N I

[0106] Still referring to Figure 8 , the metal inserts configured to be adjacent to corresponding pairs of ports spaced apart in proximity between the second jet module 108B'' and the third jet module 108C'' include: (i) a fourth insert 116D (intermediate insert) adjacent to two first intersecting ports 142A I ; and (ii) a fourth insert 116D (intermediate insert) adjacent to two third intersecting ports 142C. In the illustrated embodiment, there is no adjacent to two second non - intersecting ports 142B between the second jet module 108B'' and the third jet module 108C'' I NA metal insert, but in other embodiments, optionally, the second insert 116B (plug insert) may be positioned at that location. The metal insert configured to be adjacent between the third jet module 108C″ and the fourth jet module 108D′ adjacent to the corresponding pairs of spaced-apart ports includes: (i) the second insert 116B (plug insert) adjacent to two first intersecting ports 142A I ; (ii) the fourth insert 116D (intermediate insert) adjacent to the second non-intersecting port 142B N and the second intersecting port 142B I ; and (iii) the first insert 116A (through insert) adjacent to two third intersecting ports 142C I . The metal insert configured to be adjacent between the fourth jet module 108D′ and the second metal plate 112B adjacent to the corresponding pairs of spaced-apart ports includes: (i) the fifth insert 116E (end through insert) adjacent to the first intersecting port 142A I and the first plate port 150A; (ii) the sixth insert 116F (end plug insert) adjacent to the second intersecting port 142B I and the second plate port 150B; and (iii) the sixth insert 116F (end plug insert) adjacent to the third intersecting port 142C I and the third plate port 150C.

[0107] Referring again to Figure 6 and Figure 8 , the reconfigurable P&ID can be achieved by modularization of the metal flow reactor 100 via disassembly / assembly of different jet modules 108 and different metal inserts 116. It should be understood that many other P&ID configurations can be achieved by adjusting the number of jet modules included in the metal flow reactor, selecting the desired metal insert variants, and attaching heat exchangers to the selected or all jet modules within the metal flow reactor.

[0108] Now referring in conjunction with Figure 1 and Figure 7 to Figure 20 and Figure 21 , the metal flow reactor 100 includes one or more spacers 232 configured to position the metal inserts 116 relative to at least two plates 112 and / or jet modules 108. Figure 20 To cut a cross-section of an exemplary spacer 232 along line A-A shown in Figure 7 , which shows three metal inserts 116 supported by the spacer 232. Figure 21 Showing Figure 20 the spacer 232, where for clarity, the three metal inserts 116 are removed. As shown in Figure 20and Figure 21 As shown in Figure 21 , each spacer 232 defines a plurality of openings 234 that extend through the spacer in a first direction (e.g., the z-direction). Each opening 234 is configured to receive one of the metal inserts 116 and align the metal insert 116 with the ports 142, 150 adjacent to the metal insert 116. In an embodiment, the spacer 232 may be formed of metal (e.g., the same metal as the metal insert 116), but different materials may also be used, such as polymers suitable for the operating temperature range of the metal flow reactor 100.

[0109] Referring again to Figure 7 , the metal inserts 116 each have an insert length in the first direction (e.g., the z-direction), and the spacers 232 each have a spacer thickness in the first direction. The insert length is greater than the spacer thickness. This difference between the insert length and the spacer thickness is illustrated in Figure 7 by comparing the three metal inserts 116 and spacers 232 between the first metal plate 112A and the first jet module 108A. As shown in Figure 1 and Figure 7 , the spacer 232 is shorter than the three metal inserts 116 in the first direction. In an embodiment, the difference between the insert length and the spacer thickness is in the range of about 0.05 mm to about 0.15 mm. Each spacer 232 is positioned adjacent to or against the major outer surface 136 of one of each pair of adjacent jet modules in the metal flow reactor. When positioned between one of at least two metal plates and an adjacent jet module, the spacer 232 may be positioned adjacent to or against the major outer surface 136 of the adjacent jet module or the major plate surface 152 of one of the at least two metal plates. In an embodiment, the spacer 232 is positioned relative to the recessed portion 184 of the adjacent heat exchanger 178 and adjacent to or against the exposed portion 186 of the major outer surface 136. In an embodiment, the spacer 232 may be positioned adjacent to the major outer surface 136 using mechanical fasteners or similar fastening members.

[0110] Referring again to Figure 21 , each opening 234 of each spacer 232 includes: (i) an insertion portion 236 that is configured to receive and align the corresponding metal insert 116; and (ii) a slot portion 238 that extends from the insertion portion 236 in a second direction (e.g., the x-direction) orthogonal to the first direction and opens to one side of the spacer 232. In an embodiment, the maximum dimension of the insertion portion 236 in a third direction (e.g., the y-direction) orthogonal to the first and second directions is greater than the maximum dimension of the slot portion 238 in the third direction, such that the corresponding metal insert 116 positioned therein cannot pass through the slot portion 238.

[0111] ​​​​​​The spacer 232 can be useful during the assembly / disassembly of the metal flow reactor 100. For example, a method of assembling the metal flow reactor 100 can include using the spacer 232 to hold / position the insert while each metal plate 112 and each jet module are initially positioned on or removed from the frame 104. For example, starting only from the frame 104, the first metal plate 112A can be positioned on the frame 104 and fixed to the second support member 128 via fasteners. Next, the first spacer 232 can be positioned adjacent to the major plate surface 152 of the first metal plate 112A (e.g., via fasteners positioned to pass through the mounting holes 240 in the spacer 232) such that the opening 234 of the first spacer 232 is concentric with the plate port 150 of the first metal plate 112A.

[0112] Thereafter, the metal insert 116 selected to define the desired P&ID of the metal flow reactor 100 is inserted into the opening 234 of the first spacer 232. It should be understood that the metal insert 116 can be inserted into the opening 234 of the first spacer 232 before the first spacer 232 is positioned adjacent to the major plate surface 152 of the first metal plate 112A. Next, the first jet module 108A can be positioned on the frame adjacent to the first metal plate 112A. During the positioning of the first jet module 108A, care is taken to ensure that the protrusion 208 of each metal insert 116 is aligned with the module port 142 of the first jet module 108A, and then the first jet module 108A is pushed toward the first metal plate 112A until the metal insert 116 abuts the corresponding pair of ports between the first metal plate 112A and the first jet module 108A.

[0113] Once the first jet module 108A is pushed against the metal insert 116, the second spacer 232 can be positioned adjacent to the major outer surface 136 on the opposite side (e.g., the outlet side 164) of the first jet module 108A such that the opening 234 of the second spacer 232 is concentric with the module port 142 of the first jet module 108A. Thereafter, the metal insert 116 selected to define the desired P&ID of the metal flow reactor 100 is inserted into the opening 234 of the second spacer 232. Next, the second jet module 108B can be positioned on the frame adjacent to the first jet module 108A. During the positioning of the second jet module 108B, care is taken to ensure that the protrusion 208 of each metal insert 116 is aligned with the module port 142 of the second jet module 108B, and then the second jet module 108A is pushed toward the first jet module 108A until the metal insert 116 abuts the corresponding pair of ports between the first jet module 108A and the second jet module 108B.

[0114] This procedure is repeated for each additional jet module added to the metal flow reactor 100 until the metal insert 116 between the last jet module in the stack and the second metal plate 112B pushes against the second metal plate 112B. Once the second metal plate 112B is pushed against the metal insert, at least two tightening members 120 (e.g., threaded rods) are inserted through the first metal plate 112A, the jet module 108 (including any heat exchanger positioned thereon), and the second metal plate 112B. The contact portions 172 (e.g., threaded nuts) are then gradually tightened until a predetermined torque is reached.

[0115] Figure 22 FIG. is a simplified schematic view of a metal flow reactor 100 having a metal jet module 108 with individually controllable heat exchangers 178 configured to provide at least two different heating zones. The metal flow reactor 100 has a reactor stack including a first jet module 108A' (first module variant), a second jet module 108B'' (second module variant), a third jet module 108C' (first module variant), a fourth jet module 108D'' (second module variant), and a fifth jet module 108C' (first module variant). The process fluid flow through the metal flow reactor 100 is depicted by a plurality of arrows shown in thick line type. Figure 22 of the metal flow reactor 100. Figure 22 The metal flow reactor 100 of includes (for simplicity) four fluid inlets IN1, IN2, IN3, IN4 and one fluid outlet OUT shown as not having a metal insert 116 providing a corresponding function. As Figure 22 shown in, the metal flow reactor 100 includes a first zone HE configured to heat the reaction T1 and a second zone HE that stops the reaction, for example, at a lower temperature. T2 .

[0116] Examples

[0117] The various embodiments of the present disclosure can be better understood by reference to the following examples provided by way of illustration. The present disclosure is not limited to the examples given herein.

[0118] A metal flow reactor including 5 jet modules is assembled in accordance with the principles of the present disclosure. The metal flow reactor is tested under maximum thermodynamic constraints of applied boundary conditions (e.g., up to 200 °C and up to 50 bar). At least two different gaskets are tested. Air is used as the test fluid, and leakage is measured, requiring the pressure loss to remain < 0.2 bar / 10 minute hold time. Two heating zone configurations are used during the test: (1) one configuration in which the metal flow reactor is configured to have a single temperature zone ("single zone"); and (2) one configuration in which the metal flow reactor is configured to have two temperature zones ("double zone").

[0119] Table 1. Single Zone - Air Leakage at Fixed Temperature Increments

[0120] Leak test RT +80℃ +140℃ +200℃ RT 18 bar Normal Normal Normal Normal 34 bar Normal Normal -0.04 50 bar -0.06 -0.04 -0.09 -0.12 -0.15

[0121] Table 2. Single Zone - Air Leakage after Repeated Thermal Cycling

[0122] Leak test RT +200℃ RT +200℃ RT +200℃ RT +200℃ RT +200℃ RT 18 bar 34 bar 50 bar -0.13 -0.08 -0.08 -0.09 -0.08 × × × × -0.05 -0.08

[0123] Table 3. Double Zone - Air Leakage at Fixed Temperature Increments

[0124] Leak test RT +110℃ / +10℃ +160℃ / +10℃ +200℃ / +10℃ RT 50 bar -0.08 -0.14 -0.12 -0.11 -0.15

[0125] For both heating zone configurations (single zone and double zone), the test results indicate good reliability for air leakage. No problems were observed during the tests for the single zone configuration (Tables 1 and 2). For example, according to Table 1, when the metal flow reactor was subjected to temperatures of room temperature (''RT'' at 20 °C), +80 °C, +140 °C, and +200 °C and pressures of 18 bar, 34 bar, and 50 bar, no problems were observed. Similarly, according to Table 2, when the metal flow reactor was subjected to five temperature cycles between room temperature and +200 °C and a pressure of 50 bar, no problems were observed. No problems were observed during the tests for the double zone configuration (Table 3). For example, according to Table 3, when the metal flow reactor was subjected to zone / zone temperatures of RT / RT, +110 °C / +10 °C, +160 °C / +10 °C, +200 °C / +10 °C, and RT / RT and a pressure of 50 bar, no problems were observed.

[0126] The metal flow reactor embodiments disclosed herein have many advantages. Specifically, the mechanical architecture enables the following significant modularity: (i) reactor materials (with different metal options: stainless steel, Hastelloy, titanium, tantalum, etc.); (ii) jet module geometries, including options with only a module reaction layer (e.g., no heat exchange layer), 4 layers with a heat exchange layer integrated by sealing / fastening onto the module reaction layer, or hybrid jet modules with and without heat exchange layers with an invariant mechanical architecture; (iii) jet channel arrangements, e.g., it is possible to quickly change the P&ID of the reactor and / or it is possible to have additional fluid inlets between jet modules; (iv) temperature management, where it is possible to have several fluid temperature zones along the reactor.

[0127] The metal flow reactor embodiments disclosed herein further: (i) simplify reactor installation (few mechanical component variants) and provide simplified and local clamping around the pressurization points at the module ports, allowing reliable operation up to 200 °C and 50 bar; (ii) simplify the positioning of connections through the design of self-centering metal inserts and limit dead zones (which should be avoided with some chemicals); (iii) have large mechanical tolerances on most of the mechanical component machining; (iv) integrate the opportunity to have measurement points along the jet channels for connecting sensors (pressure sensors, flow rate, thermocouples, chemical in-line analysis, etc.); (v) utilize insulated boxes to integrate optimized thermal management (e.g., help avoid heat loss) and improve user safety with such insulated boxes (e.g., avoid potential jets from the reactor in case of problems); and (vi) reduce the mechanical architecture cost compared to conventional reactor architectures.

[0128] Although the present disclosure has been illustrated and described in detail in the drawings and foregoing description, the drawings and foregoing description are to be regarded as illustrative rather than restrictive. It is understood that only the preferred embodiments have been presented, and all changes, modifications, and other applications within the spirit of the present disclosure are desired to be protected.

Claims

1. A flow reactor, comprising: A frame; A plurality of jet modules supported by the frame, each jet module including a metal reaction layer having opposite major outer surfaces, a fluid passage disposed within the metal reaction layer, and a plurality of module ports extending between the major outer surfaces of the metal reaction layer, the module ports including intersection ports that intersect the fluid passage; At least two metal plates, the jet modules being arranged one by one between the at least two metal plates in a first direction substantially perpendicular to the major outer surfaces, the at least two metal plates being supported by the frame, wherein each metal plate has a plurality of plate ports; A plurality of metal inserts, each metal insert configured to abut a corresponding pair of ports spaced apart adjacent to each other in the first direction and including at least one intersection port such that each intersection port is abutted by at least one metal insert; And At least two tightening members extending in the first direction through the at least two metal plates and the jet modules, the at least two tightening members configured to compress the at least two metal plates and the jet modules against the metal inserts.

2. The flow reactor according to claim 1, wherein the at least two metal plates include a first metal plate fixed to the frame and a second metal plate supported by the frame, the jet modules being arranged between the first metal plate and the second metal plate.

3. The flow reactor according to any one of the preceding claims, wherein when viewed in the first direction, the module ports of each jet module are positioned between the at least two tightening members.

4. The flow reactor according to any one of the preceding claims, wherein the at least two tightening members are symmetrically positioned with respect to the module ports of each jet module.

5. The flow reactor according to any one of the preceding claims, wherein the module ports of each jet module are aligned along a common line oriented substantially perpendicular to the first direction.

6. The flow reactor according to claim 5, wherein the at least two tightening members are aligned along the common line.

7. The flow reactor according to claim 5 or claim 6, wherein the metal reaction layer of each jet module has a plurality of edges extending between its major outer surfaces, and the module ports of each jet module are positioned closer to one of the edges.

8. The flow reactor according to claim 7, wherein the common line is oriented substantially parallel to the one edge.

9. The flow reactor according to any one of the preceding claims, wherein each tightening member is elongated in the first direction.

10. The flow reactor according to any one of the preceding claims, wherein each tightening member has at least two contact portions configured to abut corresponding outer surfaces of the at least two metal plates.

11. The flow reactor according to claim 10, wherein at least one contact portion of each tightening member is configured to adjust the distance along the tightening member between the at least two contact portions.

12. The flow reactor according to claim 11, wherein each tightening member is configured as a threaded rod, and at least one contact portion of each tightening member is configured to engage a threaded nut of the threaded rod.

13. The flow reactor according to claim 12, wherein each contact portion of each tightening member is configured to engage a threaded nut of the threaded rod.

14. The flow reactor according to any one of the preceding claims, wherein each metal insert includes a first body portion that is monolithic and extends between opposite end faces of the metal insert along a central axis oriented generally parallel to the first direction.

15. The flow reactor according to claim 14, wherein the first body portion is elongated in the first direction.

16. The flow reactor according to claim 14 or claim 15, wherein the first body portion has a cylindrical shape when viewed in a cross-section oriented generally perpendicular to the first direction.

17. The flow reactor according to any one of claims 14 to 16, wherein each end face of each metal insert has a surface portion oriented generally perpendicular to the first direction.

18. The flow reactor according to claim 17, wherein each surface portion of each metal insert is configured to abut one or more of the major outer surface adjacent to each module port and the plate surface adjacent to each plate port.

19. The flow reactor according to any one of claims 14 to 18, wherein each end face of each metal insert has a protrusion extending therefrom, the protrusion being configured to be received in the corresponding pair of ports adjacent to the metal insert.

20. The flow reactor according to claim 19, wherein the protrusion of each metal insert is concentrically arranged with respect to the central axis of the first body portion.

21. The flow reactor according to any one of the preceding claims, wherein the metal insert includes a first insert configured to interchangeably abut corresponding pairs of ports, each first insert being configured to provide a first flow condition in which the ports in the corresponding pairs of ports are connected to each other in a jet flow manner.

22. The flow reactor according to any one of the preceding claims, wherein the metal insert includes a second insert configured to interchangeably abut the corresponding pairs of ports, each second insert being configured to provide a second flow condition in which the ports in the corresponding pairs of ports are isolated from each other in a jet flow manner.

23. The flow reactor according to any one of the preceding claims, wherein the metal insert includes a third insert configured to interchangeably abut the corresponding pairs of ports, each third insert being configured to provide a third flow condition in which the ports in the corresponding pairs of ports are connected to each other in a jet flow manner and connected to a first port.

24. The flow reactor according to any one of the preceding claims, wherein the metal insert includes a fourth insert configured to adjacently and interchangeably engage the corresponding pair of ports, each fourth insert being configured to provide a fourth flow condition in which (i) the ports in the corresponding pair of ports are isolated from each other in a jet flow manner and (ii) one port in the corresponding pair of ports is connected to a second port in a jet flow manner.

25. The flow reactor according to any one of the preceding claims, wherein portions of the metal reaction layer, the at least two metal plates, the metal insert, and the at least two tightening members of each jet module are formed of the same metal.

26. The flow reactor according to claim 25, wherein the same metal includes one of stainless steel, titanium, and tantalum.

27. The flow reactor according to claim 25 or claim 26, wherein one or more of the jet modules include a heat exchanger, each heat exchanger including two heat exchange layers respectively attached to the major outer surface of the metal reaction layer of each of the one or more jet modules to define a heat exchange fluid passage therebetween.

28. The flow reactor according to claim 27, wherein each heat exchange layer has a recessed portion defining an exposed portion of the major outer surface not covered by the heat exchange layer, and the module ports of each of the one or more jet modules are disposed within the exposed portion.

29. The flow reactor according to claim 27 or claim 28, wherein at least one pair of adjacent jet modules includes the heat exchanger, and the metal insert is disposed between the at least one pair of adjacent jet modules and is configured to provide a minimum gap between the heat exchangers in the first direction.

30. The flow reactor according to claim 29, wherein the minimum gap is at least 1 mm.

31. The flow reactor according to any one of claims 27 to 30, wherein the two heat exchange layers of each heat exchanger are respectively sealed to the major outer surface of the metal reaction layer of each of the one or more jet modules.

32. The flow reactor according to any one of claims 27 to 30, wherein the two heat exchange layers of each heat exchanger are respectively fastened to the major outer surface of the metal reaction layer of each of the one or more jet modules.

33. The flow reactor according to claim 32, wherein the two heat exchange layers of each heat exchanger are formed of a first metal different from the same metal.

34. The flow reactor according to any one of the preceding claims, wherein the module ports of each jet module include three module ports.

35. The flow reactor according to any one of the preceding claims, wherein the module ports include non-intersecting ports that do not intersect the fluid passageway, and wherein the corresponding pair of ports adjacent to each metal insert includes: (i) Two intersecting ports; (ii) One intersecting port and one non-intersecting port; or (iii) One intersecting port and one plate port.

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