Fluid Impact Reactor (FIRE)

Abstract

A mixing unit for a fluid device is provided. The mixing unit includes a reactant channel segment extending substantially along a first axis within a portion of the fluid device. The reactant channel segment includes a mixing portion adjacent to a segment inlet and a retaining portion fluidly connected to the mixing portion and adjacent to a segment outlet, the segment outlet being disposed downstream of the segment inlet in the flow direction of the reactant channel segment. The mixing portion includes a wall structure configured to divide the reactant channel segment into at least two sub-channels. The mixing portion also includes a mixing chamber, each of the at least two sub-channels opening through a nozzle into the mixing chamber. The nozzles are spaced apart around the mixing chamber and oriented such that the respective facing directions of the nozzles intersect substantially at the point of impact.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 726722, filed December 2, 2024, pursuant to 35 USC §119, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] This disclosure generally relates to continuous flow micro / millireas. Specifically, this disclosure relates to mixing units (micromixers) of such reactors, which are characterized by the ability to achieve high mixing efficiency while controlling pressure drop. Background Technology

[0004] Continuous flow micro / millireactors are increasingly becoming a mature and attractive option for the continuous production of chemicals and pharmaceuticals. These reactors employ microreactor technology, offering various advantages due to their small characteristic size, such as rapid heat and mass transfer and inherent safety. In microreactor systems, the mixing unit (also known as a micromixer) is a critical component. Rapid chemical reactions, primarily controlled by kinetics, are highly sensitive to mixing behavior within continuous flow chemical reactors. Poor mixing performance can lead to undesirable side reactions, negatively impacting yield and / or productivity. In microreactors, the small channel size typically results in laminar flow, where transport phenomena may be limited by diffusion.

[0005] The applicant has developed an Advanced-Flow system that enhances mixing behavior and improves heat transfer capabilities. TM An auto-reactor reactor (AFR). Aspects of AFR technology are described in U.S. Patent No. 7,939,033, the entire contents of which are incorporated herein by reference. The hybrid unit of this patent comprises a heart-shaped 2D geometry based on the split-and-reassemble (SAR) principle. Figure 22-24 Aspects of the hybrid unit disclosed in U.S. Patent No. 7,939,033 are shown. Figure 22 A three-dimensional perspective view of a portion of the process fluid passage of an existing flow reactor is shown. Figure 23 It shows Figure 22 Individual mixing units / chambers for the channels. Figure 24 It shows Figure 23 Cross-sectional perspective view of the mixing unit / chamber.

[0006] about Figure 22-24The flow reactor of a general type disclosed herein includes a module having a process fluid passage 20. The process fluid passage includes an internal surface 22. The process fluid passage 20 also includes a portion 30, which further includes an inlet 32 ​​and an outlet 34, into which process fluid flows during use and out of the portion 30 during use. The portion 20 also includes a cross-section 36 along the portion 30, defined by the internal surface 22 of the passage 20 along the portion 30. The cross-section 36 has a cross-sectional area and a cross-sectional shape 38. Along the passage 20 between the inlet 32 ​​and the outlet 34, the cross-sectional area has a plurality of minimum values ​​40.

[0007] The flow reactor described in U.S. Patent No. 7,939,033 has a unique channel design and produces good mixing performance relative to the pressure drop in a given channel or device. However, it is desirable to achieve even better performance, such as equivalent or better mixing with a lower pressure drop. Summary of the Invention

[0008] The following overview is a brief description of certain aspects of this disclosure. This overview should not be considered as a limitation on the breadth, scope, or applicability of this disclosure.

[0009] A first aspect of this disclosure includes a mixing unit for a fluid device, comprising: a reactant channel segment extending substantially along a first axis within a portion of the fluid device; the reactant channel segment including a mixing portion and a holding portion; the mixing portion adjacent to a segment inlet; the holding portion being fluidly connected to the mixing portion and adjacent to a segment outlet; the segment outlet being disposed downstream of the segment inlet in the flow direction of the reactant channel segment; the mixing portion including (i) a wall structure configured to divide the reactant channel segment into at least two sub-channels; and (ii) a mixing chamber, each of the at least two sub-channels being directed to the mixing chamber via a nozzle spaced apart around the mixing chamber and oriented such that the respective facing directions of the nozzles substantially intersect at the point of impact.

[0010] A second aspect of this disclosure includes a fluid device comprising: a reactant channel configured to deliver at least two reactants through the fluid device, the reactant channel including at least three mixing units configured according to the first aspect, the at least three mixing units being arranged sequentially, wherein the segment outlet of a preceding mixing unit is adjacent to the segment inlet of a subsequent mixing unit, such that the reactant channel segments of each mixing unit are fluidly connected and define a portion of the reactant channel. Attached Figure Description

[0011] Various exemplary embodiments of this disclosure are described in detail below with reference to the accompanying drawings. The drawings are provided for illustrative purposes only and depict only exemplary embodiments of this disclosure to facilitate understanding. Therefore, the drawings should not be considered as limiting the breadth, scope, or applicability of this disclosure. It should be noted that these drawings are not necessarily drawn to scale for clarity and ease of illustration.

[0012] Figure 1 This is a top perspective view of a fluid apparatus according to an embodiment of the present disclosure, the fluid apparatus including reactant channels for continuous flow reactions;

[0013] Figure 2 yes Figure 1 A block diagram of an embodiment of the reactant channel;

[0014] Figure 3 yes Figure 1 A top view of a fluid apparatus, wherein the top surface portion is removed to show reactant channels comprising multiple mixing units;

[0015] Figure 4 It is a top cross-sectional view of part of the inlet structure and a set of three mixing units of reactant channels;

[0016] Figure 5 According to embodiments of this disclosure Figure 4 A magnified view of a (single) blending unit in a series of three blending units;

[0017] Figure 6 According to another embodiment of this disclosure Figure 4 A magnified view of a (single) blending unit in a series of three blending units;

[0018] Figure 7 yes Figure 6 A perspective view of a reactant channel segment of a mixing unit, the reactant channel segment having a mixing portion at an upstream end and a holding portion at a downstream end;

[0019] Figure 8 yes Figure 7 An enlarged view of the mixing portion of the mixing unit, wherein the surface of the mixing portion is shown as partially transparent to show the details of the mixing portion;

[0020] Figure 9-11 Includes paired views (perspective and side views) illustrating embodiments of the mixing chambers of the mixing portions of the respective mixing units;

[0021] Figure 12 and 13 This is a perspective view showing an embodiment of the retaining portion of the reactant channel segment;

[0022] Figure 14-16 Includes paired views (perspective and side views) illustrating an embodiment of the mixing unit used in the simulation to evaluate performance properties associated with the mixing of the miscible fluid according to Example 1;

[0023] Figure 17 This is a top view of a portion of the mixing unit used in the simulation, showing the mixing of immiscible fluids according to Example 2;

[0024] Figure 18 This is a top view of a portion of a reactant channel including an inlet structure and a set of three mixing units according to an embodiment of the present disclosure;

[0025] Figure 19 This is an enlarged view of the holding portion fluidly connected to the two mixing units according to an embodiment of the present disclosure;

[0026] Figure 20 It is a top cross-sectional view of a portion of a reactant channel comprising a set of four mixing units, each mixing unit comprising only the mixing portion;

[0027] Figure 21 It is a top cross-sectional view of a portion of a reactant channel comprising a set of four mixing units, some of which consist only of a mixing portion, and one of the mixing units comprising both a mixing portion and a holding portion;

[0028] Figure 22 This is a perspective view of a portion of the reactant channel in a flow reactor based on existing technology;

[0029] Figure 23 yes Figure 22 A perspective view of the separate chambers of the prior art reactant channels; and

[0030] Figure 24 yes Figure 23 The cross-section of a separate chamber. Detailed Implementation

[0031] To facilitate an understanding of the principles of this disclosure, reference will now be made to embodiments illustrated in the accompanying drawings and described in the following written description. It should be understood that this is not intended to limit the scope of this disclosure. It should be further understood that this disclosure includes any changes and modifications to the illustrated embodiments and includes further applications of the principles disclosed herein that would commonly occur to those skilled in the art to which this disclosure pertains.

[0032] As used herein, when used for a list of two or more items, the term "and / or" means that any one of the listed items may be used alone, or any combination of two or more of the listed items may be used. For example, if a composition is described as containing components A, B, and / or C, 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.

[0033] In this document, relational terms such as first and second, top and bottom are used only to distinguish one entity or action from another, and do not necessarily require or imply any actual such relationship or order between such entities or actions.

[0034] As used herein, the term "about" means that a quantity, dimension, formulation, parameter, and other quantity and characteristic is not exact and need not be exact, but may be approximate and / or larger or smaller as required, reflecting tolerances, conversion factors, rounding, measurement errors, and other factors known to those skilled in the art. When the term "about" is used to describe an endpoint of a value or range, this disclosure should be understood to include the specific value or endpoint mentioned. Regardless of whether the numerical or range endpoints in the specification are described with "about," the numerical or range endpoints 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 relative to and independent of the other endpoint.

[0035] Concentration, quantity, and other numerical data may be expressed or presented in range format herein. It should be understood that such range format is used solely for convenience and brevity, and therefore should be flexibly interpreted to include not only the numerical values ​​explicitly stated as the limits of the range, but also all individual numerical values ​​or subranges covered within said range, as if each numerical value and subrange were explicitly stated. For example, a numerical range of “about 1 to about 5” should be interpreted to include not only the explicitly stated values ​​of about 1 to about 5, but also the individual values ​​and subranges within the indicated range. Thus, included in this numerical range are, for example, individual values ​​of 2, 3, and 4, and subranges such as 1-3, 2-4, 3-5, etc., as well as 1, 2, 3, 4, and 5 individually. The same principle applies to ranges that list only one numerical value as a minimum or maximum value. Furthermore, this interpretation should apply regardless of how broad the range is or what characteristics it describes.

[0036] Unless defined elsewhere in association with a particular term or phrase, the terms “substantially,” “basically,” and variations thereof, as used herein, are intended to indicate that the described feature is equal to or approximately equal to a value or description. For example, a surface “substantially planar” is intended to mean a planar or approximately planar surface. Furthermore, “substantially” is intended to mean that two values ​​are equal or approximately equal. In some embodiments, “substantially” may mean values ​​that differ from each other by about 10%, such as values ​​that differ from each other by about 5%, or values ​​that differ from each other by about 2%.

[0037] The directional terms used in this article, such as up, down, right, left, front, back, top, bottom, above, below, etc., are for reference only to the drawn diagrams and are not intended to imply absolute orientation.

[0038] As used herein, the terms “the,” “a,” or “an” mean “at least one,” and should not be limited to “only one” unless explicitly indicated otherwise. Thus, for example, unless the context explicitly indicates otherwise, a reference to “component” includes embodiments having two or more such components.

[0039] Figure 1-3 A fluid device 100 according to an embodiment of the present disclosure is depicted. As used herein, "fluid device" includes fluid devices ranging from micrometers (e.g., microfluidic devices) to millimeters (e.g., millifluidic devices), i.e., devices having fluid channels with a minimum size ranging from micrometers to millimeters, and preferably from about tens of micrometers to about 1.5 millimeters. The fluid device 100 includes a body 104 and a fluid path 108 disposed within the body 104. The fluid path 108 includes a reactant channel P extending through the body 104 and a plurality of fluid structures disposed along the reactant channel P, the plurality of fluid structures being in fluid communication with each other and with the reactant channel P. Each fluid structure includes an inlet 112 disposed at a first end of the reactant channel P and an outlet 116 disposed at a second end of the reactant channel P spaced apart from the first end. In an embodiment, the inlet 112 is configured to receive reactants and deliver reactants to the reactant channel P and / or additional fluid structures. In an embodiment, the inlet 112 is configured to receive at least two reactants introduced respectively through separate sub-inlets. In such an embodiment, inlet 112 is also configured to (separately) deliver the at least two reactants for a portion of inlet 112, and then reassemble the at least two reactants for delivery to reactant channel P.

[0040] The fluid device 100 is configured (e.g., via fluid path 108) to mix reactants and deliver them from inlet 112 to outlet 116 along reactant channel P in the flow direction F, as indicated by arrow F. To facilitate the mixing function of the fluid device 100, the fluid structure also includes at least one mixing unit 120 disposed along reactant channel P between inlet 112 and outlet 116. In embodiments, fluid path 108 may include additional fluid structures, such as residence time channels, separation units, and / or interfaces for online analysis. The fluid structures may be arranged adjacent to each other along fluid path 108, or spaced apart from each other along fluid path 108 while being fluidly connected via one or more segments of reactant channel P.

[0041] In an embodiment, at least one mixing unit 120 comprises a plurality of mixing units 120 located at various configurations and / or multiple positions along the reactant channel P. In an embodiment, some or all of the mixing units 120 may be arranged as one or more groups 124 mixing units 120. For example, as Figure 2 As schematically depicted in the block diagram, the mixing unit 120 in the embodiment may include a first group 124a mixing unit 120, a second group 124b mixing unit 120, and a third group 124c mixing unit 120 spaced apart from each other and continuously positioned between the inlet 112 and the outlet 116. The mixing units 120 within each group 124a, 124b, 124c may be arranged in parallel and / or in series with respect to each other.

[0042] Now for reference Figure 3 The following illustrates embodiments according to the present disclosure. Figure 1 A top view of the fluid apparatus 100, wherein the top of the main body 104 is removed to show the reactant channels P comprising mixing units 120 arranged in multiple groups 124. Figure 3 In the embodiments depicted, the mixing units 120 within each group 124 are arranged in series (e.g., continuously) with respect to each other, and the mixing units 120 of each group 124 are connected via segments of reactant channels P. The segments of the reactant channels P connecting adjacent groups 124 mixing units 120 can be straight segments, curved segments (e.g.,...) Figure 3 (as shown) and / or sections including both straight and curved portions.

[0043] exist Figure 3In the illustrated embodiment, the fluid device 100 includes twenty-two sets of 124 mixing units 120. A first set of 124a mixing units is disposed upstream of the reactant channel P near the inlet 112. The first set of 124a mixing units includes a first mixing unit 120a1 directly connected to the inlet 112, a second mixing unit 120a2 directly connected to the first mixing unit 120a1, a third mixing unit 120a3 directly connected to the second mixing unit 120a2, and a fourth mixing unit 120a4 directly connected to the third mixing unit 120a3. The fourth mixing unit 120a4 of the first set of 124a is also connected to a bend in the reactant channel P, which in turn connects to another set of 124 mixing units 120.

[0044] Still referencing Figure 3 The second group of 124b mixing units is located downstream of the reactant channel P near the outlet 116. The second group of 124b mixing units includes a first mixing unit 120b1 (directly connected to the tortuous section of the reactant channel P), a second mixing unit 120b2 (directly connected to the first mixing unit 120b1), a third mixing unit 120b3 (directly connected to the second mixing unit 120b2), a fourth mixing unit 120b4 (directly connected to the third mixing unit 120b3), a fifth mixing unit 120b5 (directly connected to the fourth mixing unit 120b4), and a sixth mixing unit 120b6 (directly connected to the fifth mixing unit 120b5). The sixth mixing unit 120b6 of the second group of 124b is also connected to the outlet 116.

[0045] Still referencing Figure 3 Twenty additional mixing units 124 are sequentially arranged between the first mixing unit 124a and the second mixing unit 124b. In other embodiments, the fluid device 100 may include fewer or more mixing units 124. Figure 3 Each group of 124 shown has 3 to 6 mixing units 120, but in other embodiments, each group of 124 may have fewer or more mixing units 120, for example, 2 to 10 mixing units or 1 to 20 mixing units per group. Each “group” of mixing units may be interchangeably referred to as a “section” of the reactant channel P. The inlet 112 and the mixing units 120 will be described in more detail later in this disclosure.

[0046] The main body 104 of the fluid device 100 can have various shapes. For example... Figure 1 and 3In the depicted embodiment, the body 104 has a plate-like shape having a top surface 128, a bottom surface 132 opposite to the top surface 128, and edges 136 connecting the top surface 128 and the bottom surface 132 along their respective peripheries. In this embodiment, the top surface 128 and the bottom surface 132 are substantially planar. In this embodiment, the body 104 may be a monolithic body comprising separate components joined together at joints (e.g., at joint planes). For example, as... Figure 1 As shown, body 104 may include a first or top body portion 140, and a second or bottom body portion 144 coupled to the top body portion 140 at a bonding plane 148. In embodiments, body 104 may be a monolithic body, such that the body has no separate components (e.g., halves of the body) coupled to each other at (observable and / or detectable) joints (such as at a bonding plane). In embodiments, reactant channel P may be a tortuous fluid channel extending through the monolithic body or the monolithic body.

[0047] The body 104 of the fluid device 100 can be formed of one or more materials selected from ceramics, metals, polymers, glass, and glass-ceramics. In embodiments where the body 104 is made of metal, the metal material can include stainless steel, such as 316L stainless steel and Hastelloy®, as well as other metals. In embodiments where the body 104 is made of polymer, the polymer material can include fluorinated polymers, such as polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (FEP), and perfluoroalkoxyalkane (PFA), as well as other polymers, such as cyclic olefin polymers (COP), polystyrene (PS), etc. In embodiments where the body 104 is made of ceramic, the ceramic material can include oxide ceramics, non-oxide ceramics, glass-ceramics, and other ceramics capable of achieving a high-density closed-cell structure or body.

[0048] Oxide ceramics are inorganic compounds of metals (e.g., Al, Zr, Ti, Mg) or metalloids (Si) with oxygen. Oxides can be combined with nitrogen or carbon to form more complex oxynitride or oxycarbide ceramics. Non-oxide ceramics are inorganic nonmetallic materials and include carbides, nitrides, borides, silicides, etc. Some examples of non-oxide ceramics that can be used for body 104 include boron carbide (B4C), boron nitride (BN), tungsten carbide (WC), titanium diboride (TiB2), zirconium diboride (ZrB2), molybdenum disilicide (MoSi2), silicon carbide (SiC), and silicon nitride (Si3N4). As used herein, a “closed-cell” ceramic body is a ceramic body in which the ceramic material of the ceramic body exhibits a closed pore topology, such that the pores or chambers in the material are isolated or connected only to adjacent pores or chambers, and are impermeable to fluids.

[0049] In embodiments where the body 104 is made of ceramic, the ceramic material may comprise any compressible powder held together by a binder and subjected to heat treatment to fuse the powder particles together to form the body. In an exemplary embodiment, the body 104 is formed of SiC. In such embodiments, the compressible powder may comprise instant-pressed (RTP) SiC powder, which includes a binder and / or other additives mixed therewith or coated thereon to facilitate pressing. Examples of such RTP SiC powders include SICS-18 manufactured by GNP Raystar, Inc., Buffalo, NY, USA; IKH 601 and 604 manufactured by Industriekeramik Hochrhein (IKH) GmbH, Würthsingen, Germany; and StarCeram Sα-SiC series SQ and RQ types manufactured by KYOCERA Fineceramics Precision GmbH, Selb, Germany.

[0050] Now for reference Figure 4-13 Further aspects of at least one mixing unit 120 are described below. For ease of description, "at least one mixing unit" may be referred to as "mixing unit" in the following text. In embodiments, for example, the mixing units 120 of a given fluid device 100 may be identical in terms of overall size and / or the dimensions of certain features thereof, or the mixing units 120 may be different. The mixing unit 120 includes a reactant channel segment P. s The reactant channel segment is located substantially along a first axis 152 within a portion of the body 104 of the fluid device 100. Figure 5 and 6 (Extension). The first axis 152 corresponds to the section P along the entire length of the mixing unit 120 in the flow direction, passing through the reactant channel segment P. s The theoretical line of the centroid of the sequential cross-section. Although the first axis 152 is depicted as a straight line in the embodiment shown herein, it should be understood that in other embodiments, the first axis 152 may include curved portions within a single plane (e.g., a two-dimensional (2D) or planar curve) and / or be curved portions not limited to a single plane (e.g., a three-dimensional (3D) or spatial curve). Reactant channel segments P of each mixing unit 120 s A portion of the reaction channel P of the fluid device 100.

[0051] The first axis 152 is intended to represent the general direction along which a given mixing unit 120 extends through the fluid device 100. It should be understood that each mixing unit 120 may have its own first axis 152, or groups of 124 mixing units 120 (e.g., as described above) may share a common first axis 152. If the mixing units 120 are arranged in parallel within a group 124, or if there are multiple groups of 124 mixing units 120 in parallel, wherein each group has mixing units 120 arranged in series (e.g., defining multiple flow paths through the fluid device 100), then there will be multiple parallel axes 152 extending through the fluid device 100. In embodiments, the first axis 152 is substantially located in what is interchangeably referred to as the axis plane 154 (…). Figure 9-11 In a single plane of the body 104. In an embodiment, the axial plane 154 is substantially parallel to the top surface 128 and the bottom surface 132 of the body 104. In an embodiment, the axial plane 154 corresponds to the midplane of the body 104 located at approximately half the orthogonal distance between the top surface 128 and the bottom surface 132. When the body 104 of the fluid device 100 is configured as a single body (e.g., referred to above), Figure 1 In the embodiment, the axial plane 154 can correspond to the mating plane 148.

[0052] Figure 4 This is a top cross-sectional view taken along the axial plane 154 of the body 104 of the exemplary fluid device 100, representing a portion of the reactant channel P according to an embodiment of the present disclosure. Figure 4 The portion of the reactant channel P shown includes an inlet 112 and a set of three mixing units 120. Figure 4 The inlet 112 and the mixing unit 120 are schematically shown using dashed boxes, which are formed by corresponding portions of the body 104 that define the inner surfaces of the inlet 112 and the mixing unit 120. Figure 5 According to embodiments of this disclosure Figure 4 An enlarged view of a single mixing unit 120 among the three mixing units 120 in the group 124. Figure 6 According to another embodiment of this disclosure Figure 4 An enlarged view of (single) mixing unit 120 among the three mixing units in the group 124.

[0053] Entrance 112 includes multiple sub-entrances, such as a first entrance portion 113 and a second entrance portion 114, as follows: Figure 4As shown. A first inlet portion 113 and a second inlet portion 114 are configured to receive a first reactant and a second reactant, respectively, and maintain separation between the first reactant and the second reactant for at least a portion of the flow through inlet 112 in the flow direction F. In embodiments, the number of sub-inlets may be greater than two, for example, three, four, or five sub-inlets, each sub-inlet configured to receive a corresponding reactant and maintain separation between the corresponding reactant and other reactants introduced via other sub-inlets for at least a portion of the flow through inlet 112. Inlet 112 also includes an outlet portion 115 through which the first and second reactants exit inlet 112 and enter fluid passage P. In embodiments, fluids introduced via sub-inlets are combined before exiting through outlet portion 115, such as... Figure 4 As shown.

[0054] Now for reference Figure 4-6 Each mixing unit has 120 reactant channel segments P s Including segment inlet 156 and in reactant channel segment P s The flow direction F is set at the segment outlet 160 downstream of the segment inlet 156. Reactant channel segment P s It also includes a mixing section 164 and a holding section 168, the mixing section being adjacent to the segment inlet 156, and the holding section being fluidly connected to the mixing section 164 and adjacent to the segment outlet 160. As described in more detail later in this disclosure, the mixing section 164 is configured to mix reactants with a high level of mixing uniformity, while the holding section 168 is configured to provide sufficient residence time for the highly mixed reactants to allow for chemical reaction before flowing to the next mixing unit 120. The holding section 168 is also configured to provide thermal management / control functions for the mixing unit 120, as described later in this disclosure.

[0055] Refer again Figure 4-6 And refer to other sources Figure 7 and 8 Describing the reactant channel segment P of mixing unit 120 s Another aspect. Figure 7 yes Figure 6 The reactant channel segment P of the mixing unit 120 s A perspective view, in which the mixing section 164 is typically located in reactant channel segment P. s The upstream end, and the portion 168 is usually set in the reactant channel segment P. s The downstream end. Figure 8 yes Figure 7 An enlarged view of the mixing portion 164 of the mixing unit 120, wherein the inner surface of the mixing portion is shown as partially transparent to show details of the mixing portion 164.

[0056] The mixing section 164 includes a wall structure 172 configured to connect reactant channel segments P s Divide into at least two sub-channels 176. Figure 5 and 6 Each of these depicts a central axis 180 of one of at least two sub-channels 176 and a series of arrows along the central axis 180 (e.g., generally indicating the flow direction through said central axis). The central axis 180 corresponds to the theoretical line of the centroid of the sequential cross-sections of the sub-channel 176 in the flow direction through the sub-channel 176. The wall structure 172 includes, on its upstream side, a gradually narrowing elongated end 184 pointing in the upstream direction.

[0057] The mixing section 164 also includes a mixing chamber 188, each of at least two sub-channels 176 leading to the mixing chamber via a nozzle 192. The nozzles 192 are spaced apart around the mixing chamber 188 (e.g., around the periphery of the mixing chamber 188) and oriented such that the corresponding facing directions 196 of the nozzles 192 substantially intersect at the impact point 200. With the nozzles 192 oriented such that the corresponding facing directions 196 substantially intersect, two reactant sub-flows flowing along the at least two sub-channels 176 and entering the mixing chamber 188 (e.g., via the nozzles 192) collide with each other to enhance mixing during operation of the fluid device 100. This mixing strategy differs from conventional micromixers, which employ a split-and-reassemble (SAR) principle, where reassembled fluid / reactant collide with obstacles to enhance mixing. One advantage of using collisional sub-flows for mixing compared to SAR, which uses obstacles, is reduced energy loss of the reactants because fluid-wall interactions are reduced when using collisional sub-flows for mixing.

[0058] Now for reference Figure 5-7 The mixing chamber 188 has a plurality of internal chamber surfaces 204 defining a chamber volume 208 of the mixing chamber 188. The nozzle 192 and the mixing chamber 188 are configured to position and / or orient the facing direction 196 of the nozzle 192 such that the impact point 200 (e.g., the intersection of the facing directions 196) is located within the chamber volume 208. The internal chamber surfaces 204 of the mixing chamber 188 include a top chamber surface 216, a bottom chamber surface 220 spaced apart from the top chamber surface 216, and a second axis 228 oriented substantially along a first axis 152 and / or an axial plane 154. Figure 9-11 A peripheral chamber surface 224 extends between the top chamber surface 216 and the bottom chamber surface 220. In an embodiment, the peripheral chamber surface 224 is arcuate and at least partially surrounds the second axis 228. In an exemplary embodiment, as shown... Figure 5 and6 As best shown, the wall structure 172 has a concave surface 232 facing downstream and defining a portion of the peripheral chamber surface 224 of the mixing chamber 188.

[0059] like Figure 8 As best shown, the mixing chamber 188 has a second axis 228 ( Figure 9-11 The chamber height h extending between the top chamber surface 216 and the bottom chamber surface 220 m Each nozzle 192 has a nozzle profile 236 defined at the intersection of the corresponding sub-channel 176 and the mixing chamber 188 (e.g., the peripheral chamber surface 224 of the mixing chamber 188). The nozzle profile 236 includes a nozzle height h parallel to the second axis 228. n and substantially orthogonal to the nozzle height h n nozzle width w n In this embodiment, the nozzle height h of the nozzle profile 236 n The chamber height h is less than 188 of the mixing chamber. m In this embodiment, the upstream portion of the nozzle profile 236 has a non-zero offset distance (d) from the upstream portion of the peripheral chamber surface 224 of the mixing chamber (188) in the downstream direction. n ).exist Figure 8 In the embodiment shown, the upstream portion of the nozzle profile 236 is the upstream edge of the nozzle profile 236.

[0060] Now for reference Figure 6-8 Reactant channel segment P s The retaining portion 168 further includes a transition section 240, through which the retaining portion 168 is fluidly connected to the mixing chamber 188. The mixing chamber 188 has a chamber opening 244, through which the transition section 240 opens to the chamber volume 208. Figure 8 As best shown, the chamber opening 244 is located downstream of the nozzle 192 and extends through the peripheral chamber surface 224 of the mixing chamber 188.

[0061] The transition section 240 has a cross-section 246 oriented perpendicular to the direction in which the retaining portion 168 extends from the mixing chamber 188 to the segment outlet 160 (e.g., perpendicular to the first axis 152). In an exemplary embodiment, the cross-section 246 of the transition section 240 has a rectangular shape, for example... Figure 8As shown. In other embodiments, the cross-section 246 may have different shapes, such as circular, stadium-shaped, trapezoidal, or other shapes. In one embodiment, the transition section 240 has a top transition surface 248, a bottom transition surface 252 spaced apart from the top transition surface 248, and an opposing side transition surface 256 extending between the top transition surface 248 and the bottom transition surface 252 and substantially parallel to the second axis 228. In one embodiment, the opposing side transition surface 256 extends outward in a downstream direction from the chamber opening 244 of the mixing chamber 188 (e.g., away from the first axis 152).

[0062] like Figure 8 As best shown, the transition section 240 has a transition section height h that is substantially parallel to the second axis 228. t In an exemplary embodiment, the transition section height h t It extends between the top transition surface 248 and the bottom transition surface 252. In this embodiment, the transition section height h t This can be the average height, maximum height, or minimum height between opposing surfaces (e.g., top surface 248 and bottom surface 252) or opposing portions of the surfaces. In this embodiment, the chamber height h of the mixing chamber 188 is... m The height h of the transition section is equal to or greater than that of the transition section 240. t The nozzle height h of nozzle profile 236. n The transition section height h can be less than or equal to the transition section height of 240. t In an exemplary embodiment, the nozzle height h n Less than the height h of the transition section t .

[0063] Refer again Figure 6-8 The retaining portion 168 has a cross-section 258 oriented perpendicular to the direction in which it extends from the mixing chamber 188 to the segment outlet 160 (e.g., perpendicular to the first axis 152). In an exemplary embodiment, the cross-section 258 of the retaining portion 168 has a rectangular shape, for example... Figure 7As shown. In other embodiments, the cross-section 258 may have different shapes, such as circular, stadium-shaped, trapezoidal, or other shapes. In one embodiment, the retaining portion 168 has a top retaining surface 260, a bottom retaining surface 264 spaced apart from the top retaining surface 260, and opposing side retaining surfaces 268 extending between the top retaining surface 260 and the bottom retaining surface 264 and substantially parallel to the second axis 228. In one embodiment, the top retaining surface 260 and the bottom retaining surface 264 of the retaining portion 168 are planar and oriented substantially parallel to each other. In one embodiment, the opposing side retaining surfaces 268 are planar and oriented substantially parallel to each other. In one embodiment, the opposing side transition surfaces 256 of the transition section 240 are configured to gradually narrow the opposing side retaining surfaces 268 to match the chamber opening 244.

[0064] In one embodiment, the cross-section 246 of the transition section 240 and the cross-section 258 of the retaining portion 168 match at the transition region 272 (e.g., correspond in size and shape). In another embodiment, the transition region 272 generally corresponds to a location along the first axis 152 where the outwardly extending opposing transition surfaces 256 of the transition section 240 intersect the substantially parallel opposing retaining surfaces 268 of the retaining portion 168.

[0065] like Figure 7 As best shown, the retaining portion 168 has a retaining portion height h extending between the top retaining surface 260 and the bottom retaining surface 264 and substantially parallel to the second axis 228. r In the embodiment, the holding portion height h of the holding portion 168 r The transition section height h of transition section 240 t Approximately equal. Still referencing Figure 7 In one embodiment, the retaining portion 168 has a retaining portion length l along the first axis 152. r It is approximately equal to or greater than the length l of the mixing portion 164 along the first axis 152. m Alternatively, in the embodiment, the length of the mixing portion is l. m Greater than the length of the holding part l r .

[0066] like Figure 7 As shown, maintain a partial length l r and the length of the mixed part l m Both are measured with reference to a baseline RL, which defines a minimum offset of the retaining portion 168 downstream of the impact point 200. In an embodiment, this minimum offset is greater than the distance between the nozzle 192 and the impact point 200 along the facing direction 196. In an embodiment, the retaining portion length lr (For example, the distance between the baseline RL and the segment exit 160) can be equal to the width w of the holding portion 168 at the segment exit 160. r-o 25 times, 50 times, 75 times, 100 times or more.

[0067] Now for reference Figure 6 and 7 The segmental inlet 156 can be positioned with reference to the tip of the gradually narrowing, elongated end 184 of the wall structure 172. For example, as Figure 6 As shown, the segmental inlet 156 can be positioned at a first distance d1 from the tip of the wall structure 172. In an embodiment, the first distance d1 can be from 0 to the width w of the mixing portion 164 at the segmental inlet 156. m-i 500% of half, for example, 0 to width w m-i 150% of half, or 0 to width w m-i 50% of half of.

[0068] Refer again Figure 7 Reactant channel segment P of mixing unit 120 s A volume ratio is provided between the holding volume of the holding portion 168 (e.g., solid grayscale fill) and the mixing volume of the mixing portion 164 (e.g., checkered surface shading). In embodiments, the volume ratio may be configured to maximize mixing uniformity and minimize pressure drop. In such embodiments, the volume ratio may be set in the range of about 1:1 to about 15:1. In some embodiments, as referenced later in this disclosure... Figure 20 and 21 The holding portion 168 can be omitted from the mixing unit 120, in which case the volume ratio between the holding volume and the mixing volume is zero (e.g., if there is no holding portion, the holding volume is zero).

[0069] Now refer to it again Figure 5 and 6 Further aspects of the at least two sub-channels 176 of the mixing section 164 and the mixing chamber 188 are described. In embodiments, the shape of the peripheral chamber surface 224 of the mixing chamber 188 may vary. For example, as Figure 5 As shown, when in a plane perpendicular to the second axis 228, for example in the axis plane 154 ( Figure 9-11 When observed within the periphery, the outer chamber surface 224 has a cross-sectional shape approximating that of a stadium (e.g., rectangles are replaced with semicircles at their opposite ends). Figure 6 As shown, when viewed in the axial plane 154, the outer chamber surface 224 has an approximately circular cross-sectional shape, such that... Figure 5 and 6The corresponding shapes of the outer chamber surfaces 224 of the mixing chamber 188 are different from each other.

[0070] exist Figure 5 and 6 In each of these, a portion 276 of the cross-sectional shape of the peripheral chamber surface 224 of the mixing chamber 188 is shown in dashed form to illustrate that the peripheral chamber surface 224 does not physically exist at the indicated location in the axial plane 154 (e.g., due to the location of the chamber opening 244), but the peripheral chamber surface 224 physically exists at indicated locations in other (parallel) planes along the second axis 228. For example, Figure 6 The circular cross-sectional shape of the outer chamber surface 224 includes a circular portion 276 depicted in dashed lines. Figure 7 and 8 In this context, the same circular portion corresponds to the physical presence of the outer chamber surface 224. Figure 6 The portion in the parallel plane above and below the cross-sectional plane (e.g., axial plane 154).

[0071] In this embodiment, the paths of the central axes 180 of at least two sub-channels 176 in the flow direction F may be different. For example... Figure 5 and 6 As shown, each of at least two sub-channels 176 has a first sub-channel segment 181 (e.g., along the central axis 180), which is disposed along an upstream portion of the sub-channel 176 and extends gradually away from the first axis 152 in the downstream direction. Each of at least two sub-channels 176 also has a second sub-channel segment 182 (e.g., along the central axis 180), which is connected to the first sub-channel segment 181 and extends abruptly toward the first axis 152 in the downstream direction.

[0072] By comparison Figure 5 and 6 It can be seen that, Figure 6 The curved transition of the path from the first sub-channel segment 181 to the second sub-channel segment 182 along the central axis 180 of each sub-channel 176 and Figure 5 The same curved transition along the path of the central axis 180 of each sub-channel 176 has a smaller radius of curvature compared to the previous path. Due to this difference in the corresponding curved transition, the nozzle 192 can be positioned and / or oriented differently around the periphery of the mixing chamber 188, which in turn can orient the facing direction 196 of the nozzle 192 differently.

[0073] By comparison Figure 5 and 6 It can be seen that, Figure 6 The angle α on the upstream side of the impact point 200 between the facing direction 196 of the nozzle 192 and the contact direction 196 is greater than 196. Figure 5 The same angle α between the facing directions 196 of the nozzle 192. Due to this difference in the corresponding angle α of the facing directions 196, the impact point 200 can be positioned differently within the chamber volume 208 of the mixing chamber 188. In embodiments, the angle α can be in the range of about 180° to about 270°, for example, about 180° to about 260°, about 180° to about 250°, about 180° to about 240°, about 180° to about 230°, about 170° to about 270°, or about 190° to about 270°, and also includes all sub-ranges and sub-values ​​between the endpoints of these ranges. In embodiments, depending on the angle α, the facing direction 196 can be parallel (e.g., when the angle α is 180°) or the facing direction 196 can be transverse (e.g., when the angle is greater than 180°).

[0074] Refer again Figure 4-13 The components 168, wall structure 172, at least two sub-channels 176, and mixing chamber 188 are kept symmetrical about a plane of symmetry of mixing unit 120. In an embodiment, the plane of symmetry is defined by a first axis 152 and a second axis 228.

[0075] Now for reference Figure 9-11 Using corresponding paired views (perspective and side views for each figure), the height h of the mixing chamber 188 is shown. m The height h of the transition section is greater than 240. t Possible reactant channel segment P s Other aspects of the mixing chamber 188. Some of these other aspects may improve the manufacturability of the mixing unit 120, while others may additionally or alternatively improve the performance of the mixing unit 120 (e.g., improve mixing uniformity and / or reduce pressure drop).

[0076] exist Figure 9 and 10 In the illustrated embodiment, the top chamber surface 216 and the bottom chamber surface 220 of the mixing chamber 188 are planar and oriented substantially parallel to each other. Figure 9 In the illustrated embodiment, the corresponding intersections of the top chamber surface 216 and the bottom chamber surface 220 with the peripheral chamber surface 224 terminate at relatively sharp edges. Similarly, the corresponding intersections of the top transition surface 248 and the bottom transition surface 252 with the peripheral chamber surface 224 terminate at relatively sharp edges. Conversely, in Figure 10In the illustrated embodiment, the respective intersections of the top chamber surface 216 and the bottom chamber surface 220 with the peripheral chamber surface 224 terminate at rounded edges (e.g., rounded edges). Similarly, the respective intersections of the top transition surface 248 and the bottom transition surface 252 with the peripheral chamber surface 224 terminate at rounded edges.

[0077] In an embodiment, for example Figure 11 As shown, one or more of the top chamber surface 216 and bottom chamber surface 220 of the mixing chamber 188 have hemispherical protrusions 280 extending outward relative to the chamber volume 208. Figure 11 In the exemplary embodiment shown, the top chamber surface 216 and bottom chamber surface 220 of the mixing chamber 118 have opposing hemispherical protrusions 280 extending outward relative to the chamber volume 208. In embodiments including the hemispherical protrusions 280, a portion of the top transition surface 248 and / or a portion of the bottom transition surface 252 disposed near the hemispherical protrusions 280 may have corresponding protruding portions 282 that extend outward and gradually narrow the hemispherical protrusions 280 into the remainder of the corresponding transition surface of the transition section 240 (e.g., the remainder of the plane of the corresponding transition surface). From a manufacturing perspective, Figure 9-11 The embodiments of the hybrid portion 164 depicted are generally ordered in increasing complexity (e.g., Figure 9 The least complicated, and Figure 11 (Most complex).

[0078] The shape of the inner chamber surface 204 (e.g., top chamber surface 216, bottom chamber surface 220, and outer chamber surface 224) of the mixing chamber 188 relative to the impact point 200, and the three-dimensional spacing (e.g., free space) between the inner chamber surface 204 and the impact point 200, are important parameters for achieving excellent mixing uniformity of the fluid device 100 employing the mixing unit 100 disclosed herein.

[0079] Still referencing Figure 9-11 And refer to other sources Figure 4-8 At least one or more of the two sub-channels 176 include a narrowing portion 183 along which the surface area of ​​a continuous cross-section of the sub-channel 176 in the downstream direction successively decreases until the sub-channel 176 adjoins the nozzle 192. In an embodiment, each of the at least two sub-channels 176 includes a narrowing portion 183. The narrowing of the narrowing portion 183 may include reducing one or more orthogonal dimensions (e.g., height and / or width dimensions) at continuous locations of the cross-section of the sub-channel 176 in the downstream direction. For example, as Figure 5 and 6As best shown, the width of subchannel 176 (e.g., in a direction perpendicular to the central axis 180) decreases sequentially in the downstream direction along each of the first subchannel segment 181 and the second subchannel segment 182.

[0080] Similarly, such as Figure 9-11 As best shown, the height of sub-channel 176 (e.g., in a direction parallel to the second axis 228) decreases sequentially in the downstream direction along at least the second sub-channel segment 182, particularly near the intersection of sub-channel 176 and mixing chamber 188. The narrowing of the narrowing portion 183 relative to the height dimension facilitates the relationship that the nozzle height h of nozzle 192... n The height h of the transition section is less than 240. t The narrowing portion 183 locally increases the flow rate of reactants through the sub-channel 176 and exiting the nozzle 192 to form a (high-speed) impinging jet of reactants, which is directed to the impact point 200 within the mixing chamber 188. A further feature of the nozzle 192 is that it can be combined with the narrowing portion 183. For example, the nozzle 192 can be associated with a narrowing portion of the flow path (e.g., narrowing portion 183) that can increase the flow velocity and direct the flow into a less constrained space, for example, where the flow velocity is increased by at least 10%, for example, at least 50%, for example, at least 100%, for example, at least 300%, relative to a wider preceding portion of the flow path.

[0081] The various features of the mixing chamber 188 disclosed herein, individually and collectively, contribute to achieving high mixing homogeneity of reactants flowing through the mixing unit 120. In the field of chemical reactors, two mixing scenarios are generally envisioned: (i) miscible fluid mixing and (ii) immiscible fluid mixing (e.g., gas / liquid mixing and immiscible fluid mixing). Regarding miscible fluid mixing, high-quality mixing is associated with the emergence of flow instabilities, such as eddy structures and / or turbulent eddies. The collision of two (high-speed) impinging jets within the mixing chamber 188 provides instability, which favors the formation of such eddies. Regarding immiscible fluid mixing, high-quality mixing is associated with the shear stress generated in the mixing zone. As disclosed herein, the impinging jets formed within the mixing chamber 188 provide unstable eddies and a high shear stress layer at the impact point 200, resulting in favorable mixing behavior. Forming an optimized collision region (a high shear stress layer with low stability) for the impinging jets requires some free space to allow the impacting reactants to diffuse freely in three dimensions.

[0082] To facilitate providing this free space, in an embodiment, the chamber volume 208 of the mixing chamber 188 is configured to provide a minimum clearance around the impact point 200. For example, one or more of the following can be configured to define a minimum clearance around the impact point 200: (i) the shape of the inner chamber surface 204 of the mixing chamber 188 (e.g., the top chamber surface 216, the bottom chamber surface 220, and the peripheral chamber surface 224) relative to the impact point 200 and (ii) the three-dimensional spacing between the inner chamber surface 204 and the impact point 200. In an embodiment, the minimum clearance is configured as a minimum spherical clearance centered on the impact point 200. In an embodiment, the minimum spherical clearance is at least twice the hydraulic diameter of one of the nozzles 192, for example, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.5, 4, 4.5, or 5 times the hydraulic diameter of one of the nozzles 192. Use a nozzle 192 with a smaller size compared to the mixing chamber (e.g., a smaller nozzle height h for nozzle profile 236). n and smaller nozzle width w n This can also help provide this kind of free space.

[0083] Now for reference Figure 12 and 13 This illustrates another aspect of the retaining portion 168. In an embodiment, the retaining portion 168 may include a plurality of mixing structures 284 configured to retain at least some of the mixture of reactants after they have flowed from the mixing portion 164. In an embodiment, one or more of the mixing structures 284 extend between the top retaining surface 260 and the bottom retaining surface 264. In an embodiment, additionally or alternatively, one or more mixing structures (not shown) extend partially between the top retaining surface 260 and the bottom retaining surface 264.

[0084] like Figure 12 As shown, the mixing structures 284 can be arranged in a sequence 288 of mixing structures 284 (e.g., one after another in a single row) substantially along the flow direction F. In an embodiment, the mixing units 284 in the sequence 288 are identical in size and / or shape. In an embodiment, when viewed in a plane perpendicular to the second axis 228 (e.g., axial plane 154), at least two of the mixing structures 284 in the sequence 288 have different dimensions (e.g., width, diameter, and / or height) and / or different shapes, for example... Figure 12As shown. For example, the first mixing structure 284a on the upstream side of the retaining portion 168 has a smaller diameter than the second mixing structure 284b disposed downstream of and adjacent to the first mixing structure. Similarly, the second mixing structure 284b has a smaller diameter than the third mixing structure 284c disposed downstream of and adjacent to the second mixing structure.

[0085] like Figure 13 As shown, the hybrid structure 284 can be arranged into an array 292 of hybrid structure 284 along the flow direction F. In an embodiment, the hybrid units 284 in the array 292 are of the same size and / or shape, for example... Figure 13 As shown. In an embodiment, when viewed in a plane perpendicular to the second axis 228 (e.g., axial plane 154), at least two of the hybrid structures 284 of the array 292 have different dimensions (e.g., width, diameter, and / or height) and / or different shapes. In an embodiment, the retaining portion 168 may include a first portion having hybrid structures 284 arranged in sequence 288 and a second portion having hybrid structures 284 arranged in array 292. The hybrid structures 284 may have various configurations, such as pillars, heat sinks, short pillars, cones, etc.

[0086] After the reactants leave the mixing section 164 of the mixing unit 120, they pass through the holding section 168, allowing the chemical reaction to occur immediately after a high level of mixing homogeneity is achieved. Maintaining good mixing quality is also important for mixing immiscible fluids, as the two phases may separate again without sufficient continuous mixing / stirring. The mixing structure 284 in the holding section 168 helps maintain emulsification.

[0087] Example

[0088] Various embodiments of this disclosure can be better understood by referring to the following examples provided with the aid of illustrations. This disclosure is not limited to the examples given herein.

[0089] Example 1 - Mixing uniformity in the mixing of miscible fluids

[0090] The mixing of the miscible fluids was simulated using the fluid simulation software Ansys Fluent. The volume of each mixing unit 120 was scaled down to approximately 5 mL, which is a typical volume for large mixing units / cells in micro / millireas (such as the commercially available Corning® Advanced-Flow™ Reactor (AFR) industrial reactor). The basic geometry of the mixing unit / cell of the AFR reactor (hereinafter referred to as "AFR ref") is referenced in the background section above. Figure 18-20The process of mixing an acid mixture (H₂SO₄ + HNO₃) and nitric acid was modeled in a simulation. These two fluids have different viscosities and densities. The acid mixture has a viscosity of 0.07 kg / (m·s) and a density of 1228 kg / m³. 3 Nitric acid has a viscosity of 0.001 kg / (m·s) and a density of 1385 kg / m³. 3 The flow rate ratio between the two fluids was set to 0.35:1. The total flow rate was set to 5 kg / min.

[0091] for Figure 14-16 The three different embodiments shown compare a set of hybrid units (e.g., Figure 3 The mixing uniformity in the first three mixing units (120a1, 120a2, 120a3) of the middle group 124a. Figure 14 The nozzle height h at nozzle 192 is depicted. n The height h of the transition section with transition section 240 t A completely two-dimensional (2D) design (“Design 1”) with no changes between the two. In Design 1, the peripheral chamber surface 224 of the mixing chamber 188 has a circular cross-sectional shape and extends between the planar top chamber surface 216 and the planar bottom chamber surface 220, such that the chamber volume 208 approximates a cylinder. As used herein, “2D design” refers to a design that exhibits a uniform channel height throughout the mixing unit and can be produced by simple 3-axis machining.

[0092] Figure 15 The nozzle height h at nozzle 192 is depicted. n The height h of the transition section with transition section 240 t There is no variation between these two simple 2.5D designs (“Design 2”). In Design 2, the top chamber surface 216 and the bottom chamber surface of the mixing chamber 188 are configured with corresponding hemispherical (dome-shaped) protrusions 280. The transition section 240 in Design 2 includes a protruding portion 282 that gradually narrows the hemispherical protrusion 280 into the remaining (planar) portion of the transition section 240. As used herein, “2.5D design” or “simple 3D” refers to a design that exhibits variable channel height but can be produced through multi-step 3-axis machining.

[0093] Figure 16 The nozzle height h at nozzle 192 is depicted. n The height h of the transition section with transition section 240 t There are changes between them, which makes the nozzle height h n Less than the height h of the transition section tA more complex 2.5D design (“Design 3”) is proposed. In Design 3, the top chamber surface 216 and the bottom chamber surface of the mixing chamber 188 are configured with corresponding hemispherical (dome-shaped) protrusions 280. The transition section 240 in Design 3 includes a protruding portion 282 that gradually narrows the hemispherical protrusion 280 into the remaining (planar) portion of the transition section 240.

[0094] Table 1 reports the results of mixing uniformity at segment outlet 116 of each mixing unit 120, as well as the pressure drop modeled for the three mixing units 120 in each of designs 1-3 and for the three mixing units of the AFR ref reactor.

[0095] Table 1. Comparison of mixing uniformity and pressure drop in test design.

[0096]

[0097] The mixing uniformity of Design 1 is almost identical to that of the AFR ref model. The voltage drop of Design 1 is slightly smaller than that of the AFR ref model. Design 3 exhibits the best mixing performance because it achieves the same mixing uniformity in one mixing unit as it can in three mixing units in the AFR ref model. The voltage drop of Design 3 is higher than that of the AFR ref model, but this voltage drop in Design 3 can be offset by reducing the number of mixing units.

[0098] Example 2 - Visualization of mixing in immiscible fluids

[0099] In terms of modeling, mixing immiscible fluids (AFRs) is very resource-intensive. Figure 17 One example shown has been achieved using water as the continuous phase (clear) and hexane as the dispersed phase (yellow). The small diameter of the formed droplets indicates effective dispersion and high-quality mixing.

[0100] The embodiments of the mixing unit 120 disclosed herein, and the fluid apparatus incorporating said mixing unit, exhibit numerous advantages and benefits. The mixing unit disclosed herein displays high mixing efficiency (uniformity). The volume ratio of the mixing and holding portions of each mixing unit can be adjusted to optimize pressure drop and mass transfer behavior. Compared to some existing configurations (e.g., heart-shaped mixing units / chambers in AFR reactors), the mixing unit disclosed herein has a more compact form. This compact form allows for a more compact package of the fluid modules, and the internal volume of each fluid module can be larger, resulting in higher reactor productivity. The mixing unit disclosed herein can be manufactured using the silicon carbide (SiC) processing and sealing processes currently used in Corning AFR fluid modules.

[0101] Although this disclosure has been illustrated and described in detail in the accompanying drawings and the foregoing description, the drawings and the foregoing description should be considered illustrative rather than restrictive. It should be understood that only preferred embodiments are presented, and protection is intended for all changes, modifications, and further applications within the spirit of this disclosure. For example, Figure 18-21 Modifications within the spirit of this disclosure are shown.

[0102] Figure 18 It is a top view of a portion of the reactant channel P, which includes inlet 112' and three mixing units 120', 120''. Figure 19 It is a top view of the 168" retaining portion that is fluidly (and directly) connected to two of the three mixing units. Figure 18 and 19 The configuration depicted enables the parallelization of mixing units 120' and 120'' to provide multiple flow paths through the fluid device. For example... Figure 18 As shown, inlet 112' includes a first inlet portion 113 and a second inlet portion 114' (e.g., sub-inlets 113, 114'), the first and second inlet portions being configured to receive a first reactant and a second reactant, respectively, and to maintain separation between the first and second reactants for at least a portion of the flow through inlet 112' in the flow direction F. Inlet 112' also includes an outlet portion 115' through which the first and second reactants exit inlet 112' and enter fluid passage P. In an embodiment, the fluid introduced via sub-inlets 113, 114' is combined before exiting through outlet portion 115', as... Figure 18 As shown.

[0103] Figure 18 The entrance 112' shown is related to the above. Figure 4 The discussion entry point 112 differs from the previous one. For example, Figure 18 The second inlet portion 114' is divided into two sub-channels, which are combined with the two sub-channels of the first inlet portion 113 at their respective outlet portions 115'. Thereafter, the first outlet portion 115' is fluidly connected to one of the sub-channels 176' of the first mixing unit 120', and the second outlet portion 115' is fluidly connected to the other of the sub-channels 176' of the first mixing unit 120'. Figure 18 The sub-channel 176' of the first mixing unit 120' shown above is related to the above. Figure 4-16 The sub-channel 176 discussed differs from the one discussed. Specifically, Figure 18 The sub-channels 176' are separate over their entire extent, while the sub-channels 176 of the mixing unit 120 discussed above are connected to each other near the outlet portion 115, for example... Figure 4As shown. Once the reactants flow through the sub-channel 176' and reach the nozzle 192, the reactants are injected into the mixing chamber 188 of the first mixing unit 120', and flow through the transition section and then into the holding section 168'.

[0104] Figure 18 The holding portion 168' of the first mixing unit 120' is related to the above regarding Figure 4-16 The discussion differs from section 168. For example, Figure 18 The holding portion 168' is configured to branch into a first branch holding portion 168a' and a second branch holding portion 168b'. For example... Figure 18 As shown, the first branch holding portion 168a' is fluidly connected to the second mixing unit 120a'', and the second branch holding portion 168b' is fluidly connected to the third mixing unit 120b''. The second mixing unit 120a'' and the third mixing unit 120b'' have similar mixing portions 164a'', 164b'' (e.g., sub-channel 176, mixing chamber 188, and transition section 240), as... Figure 18 As shown. The second mixing unit 120a'' and the third mixing unit 120b'' are configured to provide multiple flow paths through the fluid device.

[0105] The holding portion 168'' associated with the second mixing unit 120a'' and the third mixing unit 120b'' is related to the above regarding Figure 4-16 The discussion of the retention section 168 compared to and regarding Figure 18 The first mixing unit 120' differs from the holding portion 168' discussed. For example, as... Figure 19 As best shown, the retaining portion 168'' is fluidly (and directly) connected to both the second mixing unit 120a'' and the third mixing unit 120b'' via corresponding transition sections. In this configuration, reactants exiting either of the mixing chambers 188 of the second mixing unit 120a'' and the third mixing unit 120b'' can be mixed along the (common) retaining portion 168''.

[0106] Still referencing Figure 19 The retaining portion 168a'' includes one or more heat exchange features 296, which can be used to retain the top retaining surface 260 and the bottom retaining surface 264 ( Figure 7 At least one of them extends laterally and along the length l of the retaining portion. r extend.( Figure 7In one embodiment, one or more heat exchange features 296 may extend entirely between the top retaining surface 260 and the bottom retaining surface 264. In another embodiment, one or more heat exchange features 296 may extend partially from one or both of these surfaces between the top retaining surface 260 and the bottom retaining surface 264. In yet another embodiment, one or more heat exchange features 296 extend along the length l of the retaining portion. r At least 50% extension. In an embodiment, one or more heat exchange features 296 are configured as elongated heat sinks. The elongated heat sinks may extend through the retaining portion 168'', as described herein. The elongated heat sinks may also extend away from the retaining surface 260 and / or the bottom retaining surface 264 from the retaining portion 168'' to increase the surface area of ​​the retaining portion 168''. One or more heat exchange features 296 may have any shape or structure that enables the features to provide thermal management / control functions for the hybrid unit.

[0107] Figure 20 and 21 This is a top-view cross-sectional view of a portion of reactant channel P, similar to... Figure 4 The top cross-sectional view is shown, but an alternative configuration of the hybrid unit 120 is illustrated. For example, Figure 20 A configuration is shown in which each of the mixing units 120''' includes a mixing portion 164 but not a holding portion 168. In this configuration, the mixing portions 164 are directly connected in series with each other along a portion of the reactant channel P. This configuration can be provided for the entire reactant channel P or a portion thereof when continuous mixing / stirring is required. Figure 21 One configuration is shown in which some of the mixing units 120''' consist only of the mixing portion 164, for example Figure 20 As described herein, at least one of the mixing units 120 includes both a mixing portion 164 and a holding portion 168, as described throughout this disclosure. Figure 20 and 21 In the middle, the length of the mixed part is l m ( Figure 7 ) and / or maintain part length l r ( Figure 7 (If present) can vary between mixing units as needed, or only for a specific group of mixing units, to provide a customized mix.

Claims

1. A mixing unit for a fluid apparatus, comprising: A reactant channel segment extending substantially along a first axis within a portion of the fluid device, the reactant channel segment comprising a mixing portion adjacent to a segment inlet and a retaining portion fluidly connected to and adjacent to a segment outlet, the segment outlet being disposed downstream of the segment inlet in the flow direction of the reactant channel segment, the mixing portion comprising (i) a wall structure configured to divide the reactant channel segment into at least two sub-channels, and (ii) a mixing chamber, each of the at least two sub-channels being directed to the mixing chamber via a nozzle spaced apart around the mixing chamber and oriented such that the respective facing directions of the nozzles substantially intersect at the point of impact.

2. The hybrid unit according to claim 1, wherein, The mixing chamber has multiple internal chamber surfaces that define a chamber volume, and the impact point is located within the chamber volume.

3. The hybrid unit according to claim 2, wherein, The chamber volume is configured to provide a minimum spherical clearance around the point of impact, wherein the minimum spherical clearance is at least twice the hydraulic diameter of one of the nozzles.

4. The hybrid unit according to claim 2, wherein, The internal chamber surface of the mixing chamber includes a top chamber surface, a bottom chamber surface spaced apart from the top chamber surface, and a peripheral chamber surface extending substantially along a second axis perpendicular to the first axis between the top chamber surface and the bottom chamber surface.

5. The hybrid unit according to claim 4, wherein, The top chamber surface and the bottom chamber surface of the mixing chamber are planar and oriented substantially parallel to each other.

6. The hybrid unit according to claim 4, wherein, One or more of the top chamber surface and the bottom chamber surface of the mixing chamber have hemispherical protrusions.

7. The hybrid unit according to claim 4, wherein, The top chamber surface and the bottom chamber surface of the mixing chamber have opposing hemispherical protrusions.

8. The mixing unit according to any one of claims 4 to 7, wherein, The outer chamber surface of the mixing chamber is arc-shaped and at least partially surrounds the second axis.

9. The hybrid unit according to any one of claims 4 to 7, wherein, The wall structure has a concave surface facing downstream and defining a portion of the peripheral chamber surface of the mixing chamber.

10. The hybrid unit according to claims 4 to 7, wherein: The mixing chamber has a chamber height extending along the second axis between the surface of the top chamber and the surface of the bottom chamber. Each nozzle has a nozzle profile defined at the intersection of the corresponding sub-channel and the mixing chamber, and The nozzle profile includes a nozzle height that is parallel to the second axis and smaller than the height of the mixing chamber.

11. The hybrid unit according to claim 10, wherein, The upstream portion of the nozzle profile has a non-zero offset distance from the upstream portion of the peripheral chamber surface of the mixing chamber in the downstream direction.

12. The hybrid unit according to claim 10, wherein, The retaining portion further includes a transition section, through which the retaining portion is fluidly connected to the mixing chamber, the mixing chamber having a chamber opening, and the transition section opening to the chamber volume.

13. The hybrid unit according to claim 12, wherein, The chamber opening is located downstream of the nozzle and extends through the peripheral chamber surface of the mixing chamber.

14. The hybrid unit according to claim 12, wherein, The transition section has a transition section height parallel to the second axis, and wherein the height of the mixing chamber is equal to or greater than the height of the transition section.

15. The hybrid unit according to claim 14, wherein, The nozzle height of the nozzle profile is less than the transition section height of the transition section.

16. The hybrid unit according to claim 14, wherein, The retaining portion has a retaining portion height that is substantially parallel to the second axis, and wherein the retaining portion height and the transition section height are approximately equal.

17. The mixing unit according to any one of claims 1 to 7, wherein, The retaining portion has a retaining portion length along the first axis, and the retaining portion length is approximately equal to or greater than the mixing portion length along the first axis.

18. The hybrid unit according to any one of claims 1 to 7, wherein, The retaining portion has a top retaining surface, a bottom retaining surface spaced apart from the top retaining surface, and a retaining portion height extending between the top retaining surface and the bottom retaining surface and substantially parallel to a second axis perpendicular to the first axis.

19. The hybrid unit according to claim 18, wherein, The retaining portion includes a plurality of hybrid structures extending between the top retaining surface and the bottom retaining surface.

20. The hybrid unit according to claim 19, wherein, The hybrid structures are arranged in a hybrid structure sequence.

21. The hybrid unit according to claim 20, wherein, When viewed in a plane perpendicular to the second axis, at least two of the hybrid structures have different sizes and / or different shapes.

22. The hybrid unit according to claim 19, wherein, The hybrid structure is arranged as a hybrid structure array.

23. The hybrid unit according to claim 18, wherein, The retaining portion includes one or more heat exchange features that extend laterally from at least one of the top retaining surface and the bottom retaining surface and along the length of the retaining portion.

24. The hybrid unit according to claim 23, wherein, The one or more heat exchange features extend between the top retaining surface and the bottom retaining surface.

25. The hybrid unit according to claim 23, wherein, The one or more heat exchange features extend along at least 50% of the length of the retaining portion.

26. The hybrid unit according to claim 23, wherein, The one or more heat exchange features are configured as elongated heat sinks.

27. The hybrid unit according to any one of claims 1 to 7, wherein, One or more of the at least two sub-channels include a narrowed portion adjacent to the nozzle.

28. The hybrid unit according to claim 27, wherein, Each of the at least two sub-channels includes the narrowed portion.

29. The hybrid unit according to any one of claims 1 to 7, wherein, Each of the at least two sub-channels has a first sub-channel segment and a second sub-channel segment, the first sub-channel segment extending gradually away from the first axis in the downstream direction, and the second sub-channel segment connecting to the first sub-channel segment and extending abruptly toward the first axis in the downstream direction.

30. The hybrid unit according to any one of claims 1 to 7, wherein, The retaining portion, the wall structure, the at least two sub-channels, and one or more of the mixing chambers are symmetrical about the plane of symmetry of the mixing unit.

31. The hybrid unit according to any one of claims 1 to 7, wherein, The upstream side of the wall structure includes a gradually narrowing, elongated end pointing upstream.

32. A fluid device comprising: A reactant channel configured to deliver at least two reactants through the fluid device, the reactant channel comprising at least three mixing units configured according to any one of claims 1 to 7, the at least three mixing units being arranged sequentially, wherein the segment outlet of a preceding mixing unit is adjacent to the segment inlet of a subsequent mixing unit, such that the reactant channel segments of each mixing unit are fluidly connected and define a portion of the reactant channel.

33. The fluid device according to claim 32, wherein, The mixing uniformity measured at the segment outlet of the first mixing unit in sequence among the at least three mixing units is at least 0.

89.

34. The fluid device according to claim 32, wherein, The mixing uniformity measured at the segment outlet of the second mixing unit in sequence among the at least three mixing units is at least 0.

95.

35. The fluid device according to claim 32, wherein, The mixing uniformity measured at the segment outlet of the third mixing unit in sequence of the at least three mixing units is at least 0.

97.

36. The fluid device according to claim 32, wherein, The mixing uniformity measured at the segment outlet of the first mixing unit in sequence among the at least three mixing units is at least 0.

98.

37. The fluid device according to claim 32, wherein, The mixing uniformity measured at the segment outlet of the second mixing unit in sequence among the at least three mixing units is at least 0.

99.

38. The fluid device according to claim 32, wherein, The mixing uniformity measured at the segment outlet of the third mixing unit in sequence of the at least three mixing units is at least 0.999.

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