A continuous reaction microreactor

Abstract

The utility model relates to the technical field of continuous reaction micro -reactor especially, it is a kind of continuous reaction micro -reactor, it includes reaction module and control module.Reaction module contains the reaction unit of multilayer stacking, is equipped with the turbulence structure and heat exchange cavity;Control module includes pressure balance subassembly and temperature adjusting component.Turbulence structure promotes mixing efficiency through corrugated deflector and shunt channel, and heat exchange cavity passes through spiral heat conduction sheet and optimizes heat transfer.Pressure balance subassembly utilizes elastic diaphragm to adjust pressure distribution, sealing washer and connecting frame ensure sealing performance, and reinforcing rib enhances mechanical strength.Temperature adjusting component realizes accurate temperature control through thermocouple and heating wire.The utility model can significantly improve mixing efficiency, heat exchange performance and equipment stability, applicable to complex chemical reaction environment, realizes accurate control to reaction temperature, further improves reaction efficiency and product quality.

Description

Technical Field

[0001] This utility model belongs to the field of chemical equipment and micro-reaction technology, specifically a continuous reaction microreactor. Background Technology

[0002] In the development of the chemical industry, microreactors have been widely used due to their high efficiency, safety, and ease of control. However, existing continuous reaction microreactors still have some limitations in practical applications. For example, current continuous reaction microreactors on the market typically adopt a modular design or a single flow channel structure, resulting in low mixing efficiency. This makes precise control difficult in complex chemical reactions, potentially leading to incomplete reactions, low product conversion rates, and high energy consumption.

[0003] For example, a continuous reaction microreactor disclosed in Chinese invention patent (publication number: CN102405099B), published on August 26, 2015, employs a modular stacked structure. A complete microreactor system is formed by encapsulating a first frame device, a reaction unit, and a second frame device. While this design enables multi-layer stacking to improve reaction efficiency, the poor coupling between the heat exchange channel and the process fluid channel limits its adaptability to rapidly changing temperature requirements, thus restricting its application range under high-temperature and high-pressure conditions. Furthermore, this design relies on external tightening devices for sealing, which may lead to leakage risks after long-term operation, affecting the stability and reliability of the equipment.

[0004] For example, a microreactor disclosed in Chinese invention patent (publication number: CN109070041B), published on August 24, 2021, achieves material mixing by branching a high-flow-rate side flow path and merging a low-flow-rate side flow path. While this design can solve the mixing problem of materials with different flow ratios to some extent, its flow channel design is relatively complex, resulting in high manufacturing costs. Furthermore, in multiphase reactions, the lack of an effective flow-turbing structure may lead to poor mixing, thereby affecting reaction efficiency and product quality. Simultaneously, this design does not adequately consider thermal stability during long-term operation, potentially leading to material aging or deformation under high-temperature conditions, further reducing the equipment's lifespan.

[0005] The aforementioned problems indicate that current continuous reaction microreactors on the market have certain limitations in meeting the demands for efficient mixing, precise control, and long-term stable operation under complex working conditions. Therefore, this invention provides an intelligent, highly efficient mixing continuous reaction microreactor that adapts to varying environments to overcome these shortcomings and offer a more intelligent, reliable, and efficient new solution. Utility Model Content

[0006] The purpose of this invention is to solve the problems of low mixing efficiency, poor coupling between heat exchange and fluid channels, insufficient sealing reliability, and decreased material stability after long-term operation in existing continuous reaction microreactors in complex chemical reactions.

[0007] To achieve the aforementioned objectives and address the aforementioned problems, this utility model provides a continuous reaction microreactor, comprising a reaction module and a control module. The reaction module includes multi-layered stacked reaction units, each with an independent flow-disrupting structure and a heat exchange chamber. The control module includes a pressure balancing component and a temperature regulating component located on both sides of the reaction module. Through the synergistic action of the pressure balancing component and the temperature regulating component, the fluid flow state and temperature distribution during the reaction process are optimized. Connecting frames are provided at both the top and bottom of the reaction module for connecting to external pipes or equipment. The interior of the reaction module features nested flow channels, which, through the flow-disrupting structure, divide the process fluid into multiple micro-fluid regions, improving the mixing effect.

[0008] The turbulence structure includes several staggered guide plates, each with corrugated protrusions on its surface. The gaps between adjacent guide plates form flow-dividing channels. The width of these channels gradually decreases along the fluid flow direction and converges at their ends to form a mixing chamber. A heat exchange chamber is connected to the upper end of the nested flow channels, and its inner wall is provided with spiral heat-conducting fins, which are fixed to the inner wall of the heat exchange chamber by welding. Each end of the heat exchange chamber has an inlet and an outlet for connecting to external cooling or heating medium pipelines.

[0009] As a preferred embodiment of this invention, the pressure balancing assembly includes an elastic diaphragm and a support ring. The outer edge of the elastic diaphragm is fixed to the support ring by bolts, and the support ring is installed on the side wall of the reaction module via a threaded connection. A pressure sensor is located at the center of the elastic diaphragm, and the pressure sensor is connected to an external control system via a signal line. When the pressure inside the reaction module changes, the elastic diaphragm deforms, thereby adjusting the pressure distribution within the reaction module.

[0010] As a preferred embodiment of this invention, the temperature control component includes a thermocouple and a heating wire. The thermocouple is embedded in the outer wall of the reaction module for real-time monitoring of temperature changes within the reaction module. The heating wire is wound around the outer surface of the reaction module and connected to an external power source via a wire. The surface of the heating wire is covered with an insulating protective layer, which is formed by a spraying process.

[0011] As a preferred embodiment of this invention, the nested flow channel includes an inner flow channel and an outer flow channel, which are connected by a plurality of connecting holes. The diameter of the connecting holes is 0.5 mm to 2 mm, and the axis of the connecting holes forms a 45° angle with the axis of the flow channel. A filter screen is provided at the inlet end of the inner flow channel, and the filter screen is fixed to the inner wall of the flow channel by clips to intercept impurities in the fluid.

[0012] As a preferred embodiment of this invention, the reaction module is provided with sealing gaskets at both its upper and lower ends. These gaskets are made of high-temperature and corrosion-resistant fluororubber. The thickness of the sealing gasket is 3mm to 5mm, and its outer edge has a positioning groove that matches the inner wall of the connecting frame. The inner wall of the connecting frame has threaded holes, and the connecting frame is fixedly connected to the reaction module using bolts.

[0013] As a preferred embodiment of this invention, the outer wall of the reaction module is provided with reinforcing ribs, which are evenly distributed along the height direction of the reaction module. The ribs have a bottom width of 10mm, a top width of 5mm, and a height of 8mm. The reinforcing ribs are fixed to the outer wall of the reaction module by welding to enhance its mechanical strength.

[0014] As a preferred embodiment of this invention, the height of the corrugated protrusions of the guide plate is 1mm to 3mm, and the distance between two adjacent corrugated protrusions is 2mm to 5mm. The guide plate is fixed to the inner wall of the reaction unit by screws, and the number of screws is 4, evenly distributed at the four corners of the guide plate.

[0015] Compared with the prior art, the beneficial effects of this utility model are reflected in the following aspects: First, the process fluid is divided into multiple micro-fluid regions through a designed turbulence structure and nested flow channels. The corrugated protrusions and diversion channels significantly improve the fluid mixing efficiency. Second, the spiral heat-conducting fins within the heat exchange chamber increase the heat exchange area and optimize the heat transfer path, enabling the reaction module to respond quickly to temperature changes. Furthermore, the pressure balancing component regulates the pressure distribution within the reaction module through the deformation of an elastic diaphragm, effectively preventing leakage risks caused by pressure fluctuations.

[0016] The coordinated design of the sealing gaskets and connecting frames ensures the sealing performance of the reaction module under high temperature and high pressure conditions, while extending the service life of the equipment. The reinforcing ribs enhance the overall mechanical strength of the reaction module, enabling it to adapt to more complex operating conditions. Finally, the temperature control component, through the synergistic action of thermocouples and heating wires, achieves precise control of the reaction temperature, further improving reaction efficiency and product quality.

[0017] In summary, this invention, through optimized design of the reaction module and control module, solves the shortcomings of existing continuous reaction microreactors in terms of mixing efficiency, heat exchange performance, sealing reliability, and long-term stability, and provides a new solution that is intelligent, efficient in mixing, and adaptable to changing environments. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the overall structure of the continuous reaction microreactor according to an embodiment of the present invention; Figure 2 This is a cross-sectional view of the internal structure of the reaction module according to an embodiment of the present invention; Figure 3 This is a partial enlarged view of the pressure balancing assembly according to an embodiment of the present utility model; Figure 4 This is a schematic diagram of the temperature regulating component according to an embodiment of the present invention.

[0020] In the picture: 1. Reaction module; 2. Control module; 3. Connecting frame; 4. Reinforcing rib; 5. Nested flow channel; 6. Turbulence structure; 7. Heat exchange chamber; 8. Pressure balance component; 9. Temperature regulation component; 10. Elastic diaphragm; 11. Support ring; 12. Pressure sensor; 13. Thermocouple; 14. Heating wire; 15. Insulating protective layer; 16. Inner flow channel; 17. Outer flow channel; 18. Connecting hole; 19. Filter screen. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0022] This invention provides a continuous reaction microreactor, the specific implementation of which is as follows (in conjunction with the appendix). Figure 1 To be continued Figure 4 Please provide a detailed explanation. For example... Figure 1As shown, the continuous reaction microreactor includes a reaction module 1 and a control module 2. The reaction module 1 is the core component, used to achieve efficient mixing and heat exchange in the chemical reaction, while the control module 2 optimizes and controls the fluid state and temperature distribution during the reaction process through a pressure balancing component 8 and a temperature regulating component 9. The reaction module 1 consists of multi-layered stacked reaction units, each with an independent turbulence structure 6 and a heat exchange chamber 7. Connection frames 3 are located at both the top and bottom of the reaction module 1 for connection to external pipes or equipment. The inner wall of the connection frame 3 has threaded holes, and bolts are used to fix the connection frame 3 to the reaction module 1, thereby ensuring the stability of the overall structure.

[0023] Further integration Figure 2 As can be seen, the reaction module 1 has a nested flow channel 5 inside, which includes an inner flow channel 16 and an outer flow channel 17, connected by several connecting holes 18. The diameter of the connecting holes 18 is 0.5 mm to 2 mm, and their axes form a 45° angle with the axis of the flow channel. This design enables the fluid to form a vortex effect during flow, thereby promoting the mixing between different fluid regions. The inlet end of the inner flow channel 16 is equipped with a filter screen 19, which is fixed to the inner wall of the flow channel by clips to intercept impurities in the fluid and prevent them from entering the reaction module 1 and causing blockage or contamination. The nested flow channel 5 design divides the process fluid into multiple micro-fluid regions, thereby significantly improving the mixing efficiency.

[0024] The turbulence structure 6 is located in the central region of the nested flow channel 5. It includes several staggered guide vanes with corrugated protrusions on their surfaces. The gaps between adjacent guide vanes form flow-dividing channels. The width of the flow-dividing channels gradually decreases along the fluid flow direction and converges at the ends to form a mixing chamber. The height of the corrugated protrusions on the guide vanes is 1 mm to 3 mm, and the spacing between adjacent corrugated protrusions is 2 mm to 5 mm. The guide vanes are fixed to the inner wall of the reaction unit with four screws, evenly distributed at the four corners of the guide vanes. This structural design causes the fluid to undergo multiple diversions and convergences as it passes through the flow-dividing channels, thereby achieving a highly efficient mixing effect.

[0025] The heat exchange chamber 7 is connected to the upper end of the nested flow channel 5, and its inner wall is provided with spiral heat-conducting fins, which are fixed to the inner wall of the heat exchange chamber 7 by welding. The design of the spiral heat-conducting fins increases the heat exchange area and optimizes the heat transfer path, enabling the reaction module 1 to respond quickly to temperature changes. The heat exchange chamber 7 has an inlet and an outlet at both ends, which are used to connect to external cooling or heating medium pipelines, thereby achieving precise control of the internal temperature of the reaction module 1.

[0026] like Figure 3As shown, the pressure balancing assembly 8 is located on the side wall of the reaction module 1, and includes an elastic diaphragm 10 and a support ring 11. The outer edge of the elastic diaphragm 10 is fixed to the support ring 11 by bolts, and the support ring 11 is installed on the side wall of the reaction module 1 by a threaded connection. A pressure sensor 12 is located at the center of the elastic diaphragm 10, and the pressure sensor 12 is connected to an external control system via a signal line. When the pressure inside the reaction module 1 changes, the elastic diaphragm 10 deforms, thereby adjusting the pressure distribution inside the reaction module 1. This design can effectively avoid the risk of leakage caused by pressure fluctuations, while ensuring the stability of the reaction process.

[0027] like Figure 4 As shown, the temperature control assembly 9 includes a thermocouple 13 and a heating wire 14. The thermocouple 13 is embedded in the outer wall of the reaction module 1 for real-time monitoring of temperature changes within the reaction module 1. The heating wire 14 is wound around the outer wall surface of the reaction module 1 and connected to an external power source via wires. The surface of the heating wire 14 is covered with an insulating protective layer 15, which is formed by a spray coating process. This design enables precise control of the reaction temperature while preventing damage to the heating wire 14 due to external environmental influences.

[0028] like Figure 1 As shown, the cross-sectional structure of the nested flow channel 5 is clearly visible. The inner flow channel 16 and the outer flow channel 17 are connected by connecting holes 18. The arrangement of the connecting holes 18 causes the fluid to form a complex vortex effect during flow, thereby further improving the mixing effect. The arrangement of the filter screen 19 at the inlet end is also shown. It is fixed to the inner wall of the flow channel by clips and can effectively intercept impurities in the fluid.

[0029] Both the top and bottom ends of the reaction module 1 are equipped with sealing gaskets. These gaskets are made of high-temperature and corrosion-resistant fluororubber, with a thickness of 3mm to 5mm. The outer edge of the sealing gasket has a positioning groove that matches the inner wall of the connecting frame 3, ensuring sealing performance. The outer wall of the reaction module 1 is provided with reinforcing ribs 4, which are evenly distributed along the height of the reaction module 1, with a bottom width of 10mm, a top width of 5mm, and a height of 8mm. The reinforcing ribs 4 are fixed to the outer wall of the reaction module 1 by welding to enhance the overall mechanical strength of the reaction module 1.

[0030] In practical applications, the continuous reaction microreactor of this invention is suitable for various complex chemical reaction scenarios. For example, in the pharmaceutical industry, efficient mixing and precise temperature control of high-viscosity or highly reactive materials are required. During operation, the reaction module 1 is first connected to an external pipe or equipment via the connecting frame 3, ensuring that the positioning groove of the sealing gasket is perfectly matched with the inner wall of the connecting frame 3. Then, a cooling or heating medium is injected into the heat exchange chamber 7 through the inlet, and the heating wire 14 in the temperature regulation component 9 is activated. Thermocouple 13 monitors the temperature change within the reaction module 1 in real time. Simultaneously, the process fluid flows in from the inlet end of the nested flow channel 5, and after impurities are intercepted by the filter screen 19, it is divided into multiple micro-fluid regions and efficiently mixed under the action of the turbulence structure 6. The fluid is split and merged multiple times in the diversion channel, finally achieving thorough mixing in the mixing chamber. The pressure balancing component 8 adjusts the pressure distribution within the reaction module 1 through the deformation of the elastic diaphragm 10, ensuring the stability of the entire reaction process. After the reaction is complete, the fluid flows out from the outlet end of the nested flow channel 5, while the cooling or heating medium is discharged through the liquid outlet.

[0031] The outer wall of reaction module 1 is equipped with reinforcing ribs 4, whose evenly distributed design effectively enhances the overall mechanical strength of reaction module 1, enabling it to adapt to more complex working conditions. Furthermore, the high-temperature and corrosion-resistant properties of the sealing gaskets ensure the long-term stable operation of reaction module 1 under high-temperature and high-pressure conditions, extending the service life of the equipment.

[0032] To enable those skilled in the art to fully understand and implement this utility model, the specific implementation principle of this utility model is further explained below in conjunction with a specific application scenario.

[0033] In the pharmaceutical industry, continuous reaction microreactors are widely used in chemical reaction processes involving high-viscosity or highly reactive materials. Taking the synthesis process of a certain pharmaceutical intermediate as an example, this reaction needs to be carried out under high temperature and high pressure conditions, while placing extremely high demands on mixing efficiency and temperature control. The following are the specific steps and operating principles of the continuous reaction microreactor based on this invention in actual operation.

[0034] First, the reaction module 1 is connected to the external feed and discharge pipes via the connecting frame 3. The inner wall of the connecting frame 3 has threaded holes, and bolts are used to fix the connecting frame 3 to the reaction module 1, ensuring the overall structure's sealing and stability. At this point, the positioning groove of the sealing gasket perfectly matches the inner wall of the connecting frame 3, forming a reliable sealing environment to prevent leakage under high temperature and high pressure conditions. The sealing gasket is made of high-temperature and corrosion-resistant fluororubber, with a thickness of 3mm to 5mm, effectively coping with complex operating conditions.

[0035] Subsequently, the heat exchange assembly in the control module 2 is activated. Cooling or heating medium is injected through the inlet of the heat exchange chamber 7. The medium flows along the spiral heat-conducting fins, efficiently exchanging heat with the process fluid surrounding the turbulence structure 6. The spiral heat-conducting fins design increases the heat exchange area and optimizes the heat transfer path, enabling the internal temperature of the reaction module 1 to quickly reach the target value. Simultaneously, thermocouple 13 is embedded in the outer wall of the reaction module 1, monitoring internal temperature changes in real time and transmitting the data to the external control system. When the temperature deviates from the set value, heating wire 14 receives power from an external power source through wires, generating heat to compensate for the temperature changes in the reaction module 1. The surface of heating wire 14 is covered with an insulating protective layer 15 to prevent damage from external environmental influences, thus ensuring long-term stable operation.

[0036] Next, the process fluid flows in from the inlet end of the nested flow channel 5. The fluid first passes through the filter screen 19, which is fixed to the inlet of the inner flow channel 16 by clips to intercept impurities in the fluid and prevent clogging or contamination of the internal structure of the reaction module 1. After entering the nested flow channel 5, the fluid is divided into multiple micro-fluid regions. The diameter of the connecting hole 18 is 0.5 mm to 2 mm, and its axis forms a 45° angle with the axis of the flow channel. This design promotes the formation of a vortex effect during the flow process, significantly improving the mixing effect between different fluid regions.

[0037] The fluid continues to flow forward, entering the area where the turbulence structure 6 is located. The turbulence structure 6 comprises several staggered guide vanes with corrugated protrusions on their surfaces. The gaps between adjacent guide vanes form flow-dividing channels. The width of the flow-dividing channels gradually decreases along the fluid flow direction and converges at the ends to form a mixing chamber. The height of the corrugated protrusions ranges from 1 mm to 3 mm, and the spacing between adjacent corrugated protrusions ranges from 2 mm to 5 mm. This design causes the fluid to undergo multiple diversions and convergences as it passes through the flow-dividing channels, thus achieving a highly efficient mixing effect. The guide vanes are fixed to the inner wall of the reaction unit with four screws, evenly distributed at the four corners of the guide vanes, ensuring the stability of the structure.

[0038] During the reaction, the pressure balancing component 8 adjusts the pressure distribution within the reaction module 1 by the deformation of the elastic diaphragm 10. When the pressure within the reaction module 1 changes, the elastic diaphragm 10 deforms, and the pressure sensor 12 at the center monitors the pressure change in real time and transmits the signal to the external control system. The external control system adjusts the reaction conditions based on the pressure data to ensure the stability of the entire reaction process and avoid the risk of leakage due to pressure fluctuations.

[0039] After the reaction is complete, the fluid flows out from the outlet end of the nested flow channel 5, while the cooling or heating medium is discharged through the liquid outlet of the heat exchange chamber 7. The outer wall of the reaction module 1 is provided with reinforcing ribs 4, which are evenly distributed along the height direction of the reaction module 1, with a bottom width of 10mm, a top width of 5mm, and a height of 8mm. The reinforcing ribs 4 are fixed to the outer wall of the reaction module 1 by welding, enhancing the overall mechanical strength of the reaction module 1 and enabling it to adapt to more complex working conditions.

[0040] As can be seen from the above steps, the continuous reaction microreactor of this invention can significantly improve mixing efficiency, achieve precise temperature control, and ensure long-term stable operation of the equipment under high temperature and high pressure conditions in practical applications. The design of the nested flow channel 5 and the turbulence structure 6 achieves efficient mixing through vortex effect and multiple flow splitting and merging; the spiral heat-conducting plate in the heat exchange chamber 7 optimizes the heat transfer path and improves the thermal response speed; the pressure balancing component 8 adjusts the pressure distribution through the deformation of the elastic diaphragm 10, avoiding the risk of leakage; the design of the sealing gasket and reinforcing rib 4 further enhances the sealing performance and mechanical strength of the equipment. These designs work together to solve the problems of low mixing efficiency, poor heat exchange performance, and insufficient long-term stability of existing continuous reaction microreactors in complex chemical reactions, providing a new intelligent, efficient mixing solution that is adaptable to changing environments.

Claims

1. A continuous reaction microreactor, characterized in that, It includes a reaction module (1) and a control module (2). The reaction module (1) includes multi-layer stacked reaction units. Each reaction unit is provided with an independent turbulence structure (6) and a heat exchange chamber (7). The control module (2) includes a pressure balance component (8) and a temperature regulation component (9). Both the upper and lower ends of the reaction module (1) are provided with connecting frames (3). The interior of the reaction module (1) is provided with nested flow channels (5).

2. A continuous reaction microreactor according to claim 1, characterized in that, The turbulence structure (6) includes several staggered guide plates. The surface of the guide plates is provided with corrugated protrusions. The gap between two adjacent guide plates forms a flow-dividing channel. The width of the flow-dividing channel gradually decreases along the fluid flow direction and converges at the end to form a mixing cavity.

3. A continuous reaction microreactor according to claim 2, characterized in that, The heat exchange chamber (7) is connected to the upper end of the nested flow channel (5). The inner wall of the heat exchange chamber (7) is provided with spiral heat-conducting plates. The two ends of the heat exchange chamber (7) are respectively provided with liquid inlet and liquid outlet. The liquid inlet and liquid outlet are used to connect with external cooling or heating medium pipelines.

4. A continuous reaction microreactor according to claim 1, characterized in that, The pressure balancing assembly (8) includes an elastic diaphragm (10) and a support ring (11). The outer edge of the elastic diaphragm (10) is fixed to the support ring (11) by bolts. The support ring (11) is installed on the side wall of the reaction module (1) by threaded connection. A pressure sensor (12) is provided at the center of the elastic diaphragm (10).

5. A continuous reaction microreactor according to claim 1, characterized in that, The temperature control component (9) includes a thermocouple (13) and a heating wire (14). The thermocouple (13) is embedded in the outer wall of the reaction module (1). The heating wire (14) is wound around the outer wall surface of the reaction module (1) and connected to an external power source through a wire. The surface of the heating wire (14) is covered with an insulating protective layer (15).

6. A continuous reaction microreactor according to claim 1, characterized in that, The nested flow channel (5) includes an inner flow channel (16) and an outer flow channel (17). The inner flow channel (16) and the outer flow channel (17) are connected by a number of connecting holes (18). The diameter of the connecting holes (18) is 0.5 mm to 2 mm. The axis of the connecting holes (18) forms a 45° angle with the axis of the flow channel. The inlet end of the inner flow channel (16) is provided with a filter screen (19).

7. A continuous reaction microreactor according to claim 1, characterized in that, The reaction module (1) is provided with sealing gaskets at both the upper and lower ends. The sealing gaskets are made of fluororubber and have a thickness of 3mm to 5mm. The outer edge of the sealing gasket is provided with a positioning groove, which matches the inner wall of the connecting frame (3).

8. A continuous reaction microreactor according to claim 1, characterized in that, The outer wall of the reaction module (1) is provided with reinforcing ribs (4). The reinforcing ribs (4) are evenly distributed along the height direction of the reaction module (1), with a bottom width of 10mm, a top width of 5mm, and a height of 8mm.

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