chemical reactor

Abstract

Described is a chemical reactor (1), in particular of the batch type, comprising a body (2) defining a reaction space (V) for a chemical process, a head element (3) configured to seal the body (2), and a support base (5) designed to contain the body (2) and a plurality of discretization elements (4) fixed or capable of being fixed to the head element (3) and extending inside the body (2) according to a main direction of extension and configured to discretize the process action into subspaces (Vs) for releasing activation energy. The head element (3) is movable in such a way as to use the discretization elements (4) to form a controlled mixture of the reaction and a measurement of the solution, preferably a density measurement.

Description

[Technical Field]

[0001] This invention relates to chemical reactors, and more particularly to batch-type chemical reactors.

[0002] In other words, the present invention comprises a chemical reactor for the chemical engineering sector and for industrial manufacturing, research and development sectors. [Background technology]

[0003] In-batch chemical reactors differ from one another according to their operational needs. More specifically, different types of reactors are known in the sector according to the working volume and / or the nature of the reagents. In industrial situations where more than 100,000 liters / year of product are produced, production plants specifically designed to manage these working volumes are commonly employed.

[0004] Typically, new processes are studied through pilot plants that handle 5-50 liters of reagent. This "pilot" research stage is typically carried out after an R&D stage, where the volumes involved are generally 0.1-1.0 liters.

[0005] Similarly, the adoption of industrial automation in the chemical manufacturing sector has enabled the introduction of in-batch reactors to the market for R&D and pilot-stage development. In other words, while superior technological components have been introduced to the chemical sector in terms of reactor automation, reactor automation remains subject to significant obsolescence in process control.

[0006] Unfortunately, prior art reactors suffer from long times and high costs during the process from research to production.

[0007] Disadvantageously, prior art reactors result in high energy consumption during the implementation of the process.

[0008] Furthermore, prior art reactors are designed for specific production volumes, resulting in very inflexible production systems. Summary of the Invention [Problem to be solved by the invention]

[0009] The technical object of the present invention is therefore to provide a chemical reactor that can overcome the drawbacks of the prior art.

[0010] The aim of the present invention is therefore to provide a chemical reactor that allows standardizing the output of a chemical process regardless of the reaction volume.

[0011] It is also an aim of the present invention to provide a chemical reactor that allows for monitoring and manipulation of the internal reaction energy in real time.

[0012] Another aim of the present invention is to provide a chemical reactor that allows for maximum uniformity of process conditions.

[0013] Another aim of the present invention is to provide a chemical reactor that allows for three-dimensional monitoring of process and control parameters in real time. [Means for solving the problem]

[0014] The stated technical object and the specified aim are substantially achieved by a chemical reactor comprising the technical features set out in one or more of the appended claims. The dependent claims correspond to possible embodiments of the invention.

[0015] In particular, the technical objectives and aims of the present invention are substantially achieved by a chemical reactor, particularly of the batch type, including a body defining a reaction space for a chemical process and a head element configured to seal the body and create a non-contaminating working environment within the body. The head element comprises inlet and outlet conduits for reagents and products into and out of the body, respectively. The chemical reactor also includes a support base configured to contain the body and equipped with an analytical device for acquiring data related to the reagents introduced into the body, and a plurality of discretization elements fixed or capable of being fixed to the head element and extending into the body along a main direction of extension. The discretization elements are configured to discretize the process operation into subspaces of the reaction volume for releasing activation energy. Each discretization element comprises passive and / or active devices suitably distributed along the main direction of extension for manipulating the release of activation energy.

[0016] The head element is movable in such a way as to produce controlled mixing of the reaction and measurement of the solution, preferably density measurement, using discretization elements.

[0017] Advantageously, the chemical reactor allows the reaction kinetics to be manipulated in three dimensions and interpenetrate with the process volume inside the reactor.

[0018] The reactor allows the internal process energy (ie, enthalpy) to be manipulated, discretizing the reaction space into unified cells where the release of activation energy can be locally manipulated.

[0019] Advantageously, the internal energy values ​​of the process kinetics can be manipulated three-dimensionally and in real time throughout the reaction space.

[0020] Advantageously, chemical reactors allow for uniform chemical mixing within the reactor, and therefore uniform process output regardless of reaction volume.

[0021] Further features and advantages of the present invention will become more apparent in the non-limiting description that follows of one or more non-exclusive embodiments of a chemical reactor.

[0022] The description is presented below with reference to the accompanying drawings, which are provided for illustrative purposes only, without limiting the scope of the invention. [Brief explanation of the drawings]

[0023] [Figure 1] 1 is a schematic diagram of a reactor according to the present invention. [Figure 2] 1 is a schematic diagram of the components of a reactor according to the present invention. [Figure 3] FIG. 3 is another schematic diagram of the reactor components of FIG. 2. [Figure 4a-4b] 1 is a schematic diagram of the components of a reactor according to the present invention. [Figure 5] FIG. 2 is a schematic diagram of another component of the reactor. DETAILED DESCRIPTION OF THE INVENTION

[0024] With reference to the accompanying drawings, the numeral 1 indicates in its entirety a chemical reactor, in particular a batch type reactor 1.

[0025] The reactor 1 comprises a body 2 , a head element 3 , a plurality of discretization elements 4 and a support base 5 .

[0026] The body 2 defines a reaction space "V" for the chemical process, in other words the body 2 is made in the form of a tank forming a containment space for chemical reagents in which chemical reactions are carried out.

[0027] The term "chemical reagent" means any substance that participates in a reaction, which may be in a solid, liquid, and / or gaseous state. This definition also applies to chemical products.

[0028] The body 2 is preferably cylindrical. Other embodiments of the body 2 are possible depending on the operating conditions.

[0029] Preferably, the body 2 may be made of Pyrex, ie a borosilicate.

[0030] Alternatively, the body 2 may be made of Teflon.

[0031] Alternatively, the body may be made of steel.

[0032] The material of the body 2 is preferably selected according to the operating conditions of the reactor 1 .

[0033] The body 2 is inserted inside the support base 5. In other words, the support base 5 comprises a recess 5a for containing the body 2. For this reason, the support base 5 is configured to ensure the physical stability of the reactor 1.

[0034] The support base 5 comprises an analysis device 11 for obtaining data on the reagents introduced into the body 2. For example, the support base 5 comprises a system of force sensors capable of measuring the weight (and therefore the mass) of the solution. In this way, it is possible to quantify the proportion of reagent introduced into the body 2 in terms of volume, knowing its density. This solution is advantageous when there is no flow meter in the reactor 1.

[0035] The support base 5 may alternatively (or additionally) be provided with other types of analysis devices 11, both passive and active. For example, it is possible to use load cells for measuring weight positioned below the body 2, or it may comprise active elements, such as microwave or ultrasound emitters or optical analysis elements for spectroscopy, located along the walls of the body 2 and in contact with the periphery of the body 2.

[0036] Preferably, the support base 5 may comprise a support structure 5b, such as that shown in Figure 5. The support structure 5b is configured to secure the support base 5 to the head element 3 in such a way as to ensure correct positioning of the head element 3 on the support base 5.

[0037] The number of support elements 5b can be changed depending on requirements and can be used for electrical wiring of components for transferring data (e.g., load cells placed on the surface of the recess 5a in contact with the base portion of the body 2, etc.) In other words, there is a connector 5c for electrical signals near the contact portion between the support base 5 (i.e., the support elements 5b) and the head element 3.

[0038] The support element 5 b may for example be made in the form of a lateral support column which may be equipped with a system of actuators or hydraulic pistons or other devices for correct positioning of the head element 3 on the support base 5 .

[0039] In other words, the support base 5 (i.e., the support element 5b) comprises a fastening system 5d between the support base 5 and the head element 3. The fastening system 5d may comprise a linear actuator or a hydraulic piston or a magnetic or mechanical locking system to form an anchor between the support base 5 and the head element 3.

[0040] Preferably, the support element 5b may comprise further sensors or active elements, such as microwave emitters.

[0041] As shown for example in FIG. 5, the support base 5 preferably comprises support elements 12 for mechanical stability of the reactor 1 .

[0042] The head element 3 is configured to seal the body 2. More specifically, the sealing is performed using the support base 5. In this way, the head element 3 makes it possible to obtain a non-contaminating working environment inside the body 2. Preferably, the head element 3 is coupled or coupleable to an external vacuum pump (rotary type) in such a way as to create the above-mentioned non-contaminating working environment.

[0043] The head element 3 comprises an inlet conduit 3a and an outlet conduit 3b for the reagents and the product, respectively. In other words, the inlet conduit 3a is used to insert the reagents into the body 2, and the outlet conduit 3b is used to remove the product from the body 2.

[0044] Preferably, the inlet conduits 3a and outlet conduits 3b are equipped with solenoid valves 10 and / or linear actuators configured to control the flow of incoming reagents and outgoing products.

[0045] The head element 3 is movable in such a way as to achieve controlled mixing of the reaction and measurement of the solution, preferably density measurement, using the discretization element 4 (as will be explained in more detail below).

[0046] Preferably, the head element 3 defines a stationary region "S" in which the inlet conduit 3a and the outlet conduit 3b are provided, and a dynamic region "D" configured to rotate about the axis of the extension of the chemical reactor 1, as shown for example in the accompanying drawings.

[0047] Dynamic region "D" is rotated by an electric motor 14 which is specially sized to ensure controlled mixing of the reaction.

[0048] The dynamic region "D" comprises discretized elements 4. Preferably, the dynamic region "D" is made in the form of a rotating disk. Preferably, the stationary region "S" is made in the form of a ring which contains the dynamic region "D".

[0049] Preferably, the head element 3 also comprises an anchor 16 for a system 17 for rotation of the dynamic region "D" which avoids undesired movements of the dynamic region "D".

[0050] On the surface of the head element 3 facing towards the interior of the reaction space “V” (ie of the body 2 ), there may be a fixing portion 6 for the discretization element 4 .

[0051] Preferably, the head element 3 comprises a first electronic control unit 7a for processing the acquired data and for controlling the discretization element 4 in response to the acquired data.

[0052] Preferably, between the stationary region "S" and the dynamic region "D" there is a rotary connection 15 for powering the first electronic control unit 7a, as shown in Figure 2. Preferably, the rotary connection 15 is positioned coaxially with respect to the rotating shaft of the rotation system 17.

[0053] A first electronic control unit 7a (preferably one or more PCBs) is required for processing (i.e., pre-processing) the acquired data, and further configured for controlling the discretization element 4 in response to the acquired data.

[0054] Preferably, the first electronic control unit 7a is located in the static region "S." Alternatively, the first electronic control unit 7a may be located in the dynamic region "D."

[0055] The reactor 1 also preferably includes a second electronic control unit 7b (preferably one or more PCBs) configured for remote control of the reactor 1 using control software based on web application technology. In other words, the second electronic control unit 7b communicates via wireless means 13 with a user interface for controlling the reactor 1.

[0056] Advantageously, the use of the second electronic control unit 7b eliminates direct interaction between the operator and the reactor 1.

[0057] The first electronic control unit 7a and the second electronic control unit 7b may be connected to each other by suitable wires or communicate with each other by wireless technology 13.

[0058] All electromechanical devices necessary for the operation of reactor 1 are preferably housed in stationary area "S" (eg solenoid valves 10, flow meters, pressure measuring devices, motors 14, etc.).

[0059] Preferably, the head element 3 may comprise a lithium battery 8 which in turn is connected to a connection 9 for an external power source.

[0060] A plurality of discretizing elements 4, which are or can be fixed (preferably using fixing portions 6) to the head element 3 (preferably in the dynamic region "D"), extend inside the body along a main direction of extension "P". Preferably, each discretizing element 4 extends along the main direction of extension "P" with an interpenetrating length across the reaction space "V". In other words, the length of the discretizing element 4 extends parallel to the axis of the extension of the body 2.

[0061] The discretization element 4 is configured to discretize the process operation into sub-spaces "Vs" of the reaction space "V" for releasing activation energy, for example as shown in Figure 4a.

[0062] Each discretization element 4 comprises passive devices 4a and / or active devices 4b, which are preferably distributed along the main direction of extension to manipulate the release of activation energy.

[0063] The term "passive device" 4a may be used to mean any type of reading sensor, for example the sensor may be a temperature or acid / base sensor.

[0064] The term "active device 4b" may refer to, for example, a microheater or a microcooler, etc. Preferably, the active device 4b may be, for example, a Peltier cell.

[0065] In other words, the discretization elements 4 are configured to emit activation energy of the thermal type. Alternatively, the discretization elements 4 may be configured to emit activation energy of the microwave or ultrasonic type.

[0066] Preferably, each discretization element 4 comprises an inner core 4c with passive devices 4a and active devices 4b, and an outer casing 4d, preferably made of Pyrex, Teflon or steel.

[0067] In the accompanying drawings, the discretizing element 4 has an elongated cylindrical shape with rounded tips depending on the operating conditions, although other shapes are possible.

[0068] The discretization elements 4 are distributed in the reaction space "V" in such a way as to form a three-dimensional matrix of passive devices 4a and / or active devices 4b. In this way, the discretization elements 4 can discretize the process operation in said subspace, being distributed in an ordered manner. Depending on the operating conditions, the distribution of the passive devices 4a and / or active devices 4b can be modified.

[0069] Preferably, each discretization element 4 (even more preferably each passive device 4a and / or active device 4b) is controlled independently and / or by PID control (Proportional-Integral-Derivative). In other words, the first electronic control unit 7a may include one or more modules 7c that communicate with one or more of the discretization elements 4. Preferably, each discretization element 4 comprises electrical contacts for connection with the first electronic control unit 7a. As shown, for example in the accompanying drawings, the electrical contacts are integrated with the fixed part 6.

[0070] In this way, it is possible to achieve scalability of the results obtained, which is linked to the possibility of reproducing the conditions necessary for the reaction regardless of the total volume processed. More specifically, thanks to the use of discretized elements 4, it is possible to obtain a local manipulation of the physics of the chemical reaction.

[0071] Furthermore, the above-described structure allows the transfer of activation energy directly inside the body 2, eliminating the possibility of undesired dispersion.

[0072] The discretization elements 4 allow a distribution of energy to be obtained that can have a catalytic effect on the reaction, reducing process time and lowering costs.

[0073] Advantageously, the present invention overcomes the shortcomings of the prior art.

[0074] Advantageously, reactor 1 allows for manipulation of the internal energy of the process, discretizing the reaction space "V" into unified cells (subspaces "Vs") in which it is possible to locally manipulate the release of activation energy. In other words, reactor 1 allows for manipulation of reaction kinetics in three dimensions.

[0075] Advantageously, reactor 1 allows for uniform chemical mixing within the reaction space "V", allowing for standardization of process output regardless of reaction volume.

[0076] Advantageously, reactor 1 allows for monitoring and manipulation of the internal reaction energy in real time.

[0077] Advantageously, reactor 1 makes it possible to obtain a rapid transfer of the process from the research stage to the production stage.

[0078] Advantageously, the reactor 1 makes it possible to obtain maximum uniformity of the process conditions and three-dimensional monitoring of the process and control parameters of the reaction.

[0079] Advantageously, the reactor 1 makes it possible to obtain a direct measurement of the flow of heat produced by the chemical reaction.

[0080] Advantageously, reactor 1 makes it possible to obtain a reduction in energy consumption through process innovation.

[0081] Advantageously, the presence of the reactor 1 in an industrial plant makes it possible to obtain a highly versatile plant for multiple processes.

[0082] Furthermore, the present invention advantageously makes it possible to obtain a circular economy in the chemical manufacturing sector.

[0083] Advantageously, reactor 1 makes it possible to make the output of the chemical process independent of a particular operator. In particular, electronic control units 7a and 7b (i.e., passive devices 4a and active devices 4b) make it possible to use the main automation functions to monitor process costs in terms of energy and raw materials, thus obtaining a quantitative assessment of production efficiency.

Claims

1. A batch type chemical reactor (1), comprising: a body (2) defining a reaction space (V) for a chemical process releasing internal reaction energy; a head element (3) configured to seal the body (2) and to create a non-contaminating working environment inside the body (2), the head element (3) comprising inlet and outlet conduits (3a) and (3b) for reagents and products into and out of the body (2), respectively; a support base (5) configured to contain the body (2) and equipped with an analysis device (11) for acquiring data related to the reagent introduced into the body (2); a plurality of discretization elements (4) fixed or capable of being fixed to the head element (3) and extending inside the body (2) according to a main direction of extension, configured to discretize the operation of the chemical process in the reaction space (V) in order to release internal reaction energy, each discretization element (4) comprising passive devices (4a) and / or active devices (4b) distributed along the main direction of extension; Including, the head element (3) is movable so as to control the mixing inside the chemical reactor (1) and measure the density of the solution inside the chemical reactor using the discretization element (4); the passive device is a temperature sensor or an acidity / baseness sensor; the active device is a microheater, a microcooler, or a Peltier cell; Chemical reactor (1).

2. 2. The chemical reactor (1) according to claim 1, wherein the head element (3) defines a stationary zone (S) with inlet (3a) and outlet (3b) conduits and a dynamic zone (D) configured to rotate about the axis of the extension of the chemical reactor and comprising the discretization element (4), the dynamic zone (D) being made in the form of a rotating disk.

3. 3. The chemical reactor (1) according to claim 1 or 2, wherein the discretization elements (4) are distributed in the reaction space (V) in such a way as to define a three-dimensional array of passive devices (4a) and / or active devices (4b) for discretizing the operation of the chemical process, each passive device (4a) and / or active device (4b) being controlled independently and / or by PID control.

4. 4. The chemical reactor (1) according to any one of claims 1 to 3, wherein each discretization element (4) extending along the main direction of extension with an interpenetrating length throughout the reaction space (V) comprises an inner core (4c) equipped with the passive devices (4a) and active devices (4b), and an outer casing (4d) made of Pyrex, Teflon or steel.

5. 5. The chemical reactor (1) according to any one of claims 1 to 4, wherein the head element (3) comprises a first electronic control unit (7a) for processing the acquired data and for managing the discretization element (4) in response to the acquired data.

6. 6. The chemical reactor (1) of claim 5, wherein the reactor (1) also comprises a second electronic control unit (7b) configured for remotely controlling the reactor (1) using control software.

7. 7. The chemical reactor (1) according to any one of claims 1 to 6, wherein the inlet conduits (3a) and outlet conduits (3b) are equipped with solenoid valves (10) and / or linear actuators configured to manage the flow of inlet reagents and outlet products.

8. 8. Chemical reactor (1) according to any one of claims 1 to 7, wherein the support base (5) may also comprise elements operating along the wall of the body, which are microwave or ultrasound emitters or optical elements for spectroscopic analysis.

9. 9. The chemical reactor (1) according to any one of claims 1 to 8, wherein the support base (5) comprises a support structure (5b) configured to fix the support base (5) to the head element (3) in such a way as to ensure correct positioning of the head element (3) on the support base (5).

10. Chemical reactor (1) according to any one of claims 1 to 9, wherein the discretization elements (4) are configured for releasing the internal reaction energy of the thermal, microwave or ultrasonic type.

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