System and method for in-SITU generation of unstable chemical compounds

Abstract

The present invention relates to a system, method, and application for the in-situ generation and use of unstable chemical compounds, defined as species whose concentration decreases through spontaneous decomposition at a rate greater than 0.1 mg / L per day. The system comprises a microchannel reactor integrated into a conductive flange, in thermal contact with the fluid to be treated, which serves as a cooling medium, reducing the distance between production and dosing to less than 1 m. Precursors can be supplied in liquid, gaseous, solid, or multiphase phases, enabling on-demand generation of peracids. Sensors and control algorithms optimize the process. The system finds application in disinfection, advanced oxidation, reduction, coagulation, neutralization, and treatment of municipal, industrial, food, and pharmaceutical water.

Description

[0001] SYSTEM AND METHOD FOR IN-SITU GENERATION OF UNSTABLE CHEMICAL

[0002] COMPOUNDS

[0003] The present invention relates to a system and method for the in- situ generation of unstable, partially stable, moderately unstable, and unstable physical, chemical, and biological compounds and reagents. These reagents can be generated using fluid precursors of various physical natures, such as liquids, gases, solids, and mixtures thereof .

[0004] The on-site production of these single compounds or mixtures, called reagents, is a widely used practice in water treatment, as it represents an efficient and effective solution for optimizing chemical procurement and management costs. Consider the case of compounds or mixtures such as performic acid (PFA) , chloramines, peracetic acid (PAA) , and sodium hypochlorite, which are frequently generated directly on-site for disinfection and oxidation applications of municipal and industrial water. Other examples concern the generation of liquid and / or gaseous solutions, at various levels and concentrations, of: ozone (O3), hydrogen peroxide (H2O2), chlorine dioxide (C102) , sulfuric acid (H2SO4) , nitric acid (HNO3), hydrocloric acid (HC1) , calcium chloride (CaCl2) , iron chloride (FeCl3), aluminum sulfate (A12(SO4)3), sodium hypobromite (NaOBr) , sulfur dioxide (S02), sodium bicarbonate (NaHCO3) , potassium permanganate (KMnO4), sodium chlorite (NaC102), bromine (Br2), and magnesium chloride (MgCl2) . The ability to produce these compounds in situ allows for greater operational flexibility and cost optimization, reducing the need for transportation and storage of chemical reagents .

[0005] In its various configurations, the system described allows for the in-situ generation of a wide range of unstable chemicals used in water treatment and other industrial applications. Conventional systems for generating these compounds and reagents, even in the form of mixtures, have several limitations. First, the formation reactions are often highly exothermic, producing significant amounts of heat which, if not properly managed, can compromise the safety and efficiency of the process. Ineffective dissipation of excess heat can lead to localized overheating, accelerating the decomposition of the products and reducing their yield, compromising their safe use.

[0006] In further embodiments, the system and method of the present invention may be configured for the in-situ generation of a wide range of unstable chemical compounds, including, by way of example and not limitation: Peracids: performic acid (PFA) , peracetic acid (PAA) , Caro's acid (H2SOs), perpropionic acid, perbutyric acid, perbenzoic acid, and other aliphatic or aromatic peracids. Inorganic oxidants: ozone (O3), hydrogen peroxide (H2O2), chlorine dioxide (C102) , sodium hypobromite (NaOBr) , sodium chlorite (NaC102) , potassium permanganate (KMnO4) , bromine (Br2). Combined oxidizing compounds: chloramines (mono-, di- and trichloramines) , iodamines and iodinated oxidizing species (I2, HIO), activated mixtures such as ozone + H2O2(Peroxone process) or chlorine + H2O2. Radical species: hydroxyl radicals (*0H) , sulfate radicals

[0007] (S04»- ) , halogen radicals (Cl», Br») , carbon radicals and hydrate-electronic radicals (eaq-) produced electrochemically, photocatalytically or radiolytically. Unstable reducing agents: sulfur dioxide (S02), sulfite (Na2SO3) , bisulfite (NaHSO3) , iron (II) species (Fe2 +) or magnesium (II) generated from sacrificial electrodes, molecular hydrogen (H2) from electrolytic processes. Strong acids and bases: sulfuric acid (H2SO4), nitric acid (HNO3), hydrochloric acid (HC1) , alkali hydroxides such as Naoh and KOH, obtainable in situ through electrochemical processes. . Coagulants and functional salts: ferric chloride (FeCl3) , aluminum sulfate (A12(SO4)3), calcium chloride (CaCl2) , magnesium chloride (Mg2Cl2) .

[0008] The possibility of generating such compounds directly in channel microreactors, optionally assisted by heterogeneous catalysts, conductive electrodes, or photocatalytic modules, allows for a significant expansion of the application field of the present invention, including not only advanced oxidation processes, but also reducing treatments, disinfection, coagulation / precipitation, and acid-base neutralization. In all cases, the short distance between the generation point and the point of use (< I m) , preferably less than 0.1 m, ensures the stability of the produced compound and maximizes its application efficacy.

[0009] In further embodiments, the chemical precursors introduced into the microchannel reactor can be supplied not only in single liquid, gaseous, or solid phases, but also in multiphase combinations. Specifically, the system can utilize two-phase gas-liquid mixtures (e.g. , oxygen or gaseous ozone with liquid acids) , gas-solid mixtures (ozone or gaseous chlorine with solid catalysts) , liquid-solid mixtures (liquid acids with catalyst powders or sacrificial electrodes) , or even three-phase gas-liquid-solid systems. This multiphase configuration optimizes the reaction kinetics, expands the range of unstable compounds that can be generated, and increases the system application flexibility.

[0010] Another critical issue is the instability and rapid decomposition of many of these chemicals, which leads to a loss of effectiveness over the time from their production (similar to the generator exit point, defined as time zero) to the point of actual use in water treatment (similar to the point of release into the contaminated fluid being treated, defined as time t) . This phenomenon leads to a loss of product effectiveness and the need for overdosing to compensate for the decay, resulting in increased operating costs and potential environmental impacts. Indeed, current systems often have a significant distance between the point of chemical generation and the point of dosing into the fluid being treated. This physical separation increases the product residence time before use, exacerbating decomposition problems and further reducing overall treatment efficiency.

[0011] On the other hand, many existing systems lack precise, real-time control of reaction conditions, limiting the ability to optimize process parameters based on variations in the characteristics of the water to be treated or the operational needs of the plant.

[0012] It is recognized that a system and method for the in-situ generation of unstable chemicals is needed that overcomes one or more of these challenges, enabling more efficient, safe, and controlled production of chemical reagents directly at the point of use in water treatment .

[0013] The device described also allows for the activation of chemical compounds through the mixing of catalysts or activators, both homogeneous and heterogeneous. This approach increases the efficiency of the production and treatment processes for the generated compounds. For example, formic acid can be dosed into peracetic acid to form mixtures of various peracids, or powdered activated carbon can be dosed to activate catalytic ozonation. Furthermore, the system supports the dosing of coagulants to activate oxidants such as chlorine and peracetic acid, or the dosing of oxidants to activate coagulants in the form of hydroxides, and so on. This flexibility allows for optimized production yields and improved overall treatment efficiency .

[0014] In a further embodiment, the micro-channel reactor can be coated or filled with solid catalytic materials of acidic character, suitable for accelerating the production reaction of the unstable chemical compound, for example the per-acidif ication reaction between formic acid and hydrogen peroxide, leading to the in-situ formation of performic acid.

[0015] For the purposes of this invention, "unstable chemical compound" means a compound or mixture of compounds whose concentration varies spontaneously over time due to decomposition, transformation, or side reactions, with a degradation rate greater than 0.1 mg / L per day, preferably greater than 1 mg / L per day, measured under standard environmental conditions (20-25 °C, atmospheric pressure, no further feed to the compound) . This definition includes both pure compounds and mixtures, oxidizing or reducing, radical or molecular, acidic or basic, produced in the liquid, gaseous, or solid phase.

[0016] Such materials include, but are not limited to: acidic ion exchange resins (Amberlyst®, Dowex®, Nafion®) , acidic zeolites (ZSM- 5, Beta, Y) , acidic metal oxides such as sulfated zirconia, modified titania, or hydrated niobia, carbons functionalized with sulfonic acid groups (-SO3H), as well as supported heteropolyacids (e.g. , silica-anchored H3PW12O40, MCM-41, or activated carbons) . The use of such heterogeneous catalysts enables high catalytic activity, chemical stability in an oxidizing environment, and ease of integration into the continuous- flow reactor, with reduced need for downstream separation.

[0017] Catalysts can be implemented in different configurations:

[0018] (i) coating ("wash- coat") of the walls of the micro-channels with thin films of catalytic material,

[0019] (ii) insertion of impregnated granular or monolithic particulate matter inside the channel, (iii) deposition on structured supports (lattices, honeycombs or porous inserts) suitable for maximizing the specific surface area and contact efficiency with the reagents.

[0020] These configurations are compatible with the modular flanged architecture of the system and can be chosen according to the operating conditions and the desired degree of intensification.

[0021] Some catalytic materials, such as acidic zeolites and niobium phosphates, in addition to providing Bronsted acid sites, exhibit the ability to adsorb or modulate the presence of water in the microstructure. This property is particularly advantageous in the per-acidif ication reaction, as shifting the equilibrium through selective removal or confinement of water increases the yield of performic acid. Other materials, such as sulfated zirconia or Nafion®, are instead characterized by super-acidity and stability in an oxidizing environment, reducing phenomena of non-selective decomposition of H2O2.

[0022] The heterogeneous catalytic activity combines synergistically with the peculiar thermal management of the micro-channel reactor: the fluid to be treated acts as a conductive cooling medium, dissipating the heat of the exothermic peracid- forming reaction and maintaining operating temperatures below 40-50 °C.

[0023] This configuration allows not only to stabilize the unstable chemical, but also to avoid "hot-spot" phenomena typical of conventional reactors, making the system intrinsically safer and more efficient .

[0024] The combination of (a) heterogeneous acid catalysis, (b) intensifying microstructure, and (c) conductive cooling by the target fluid enables on-demand production of performic acid under controlled conditions of residence time (1-10 seconds) , minimal distance between production and dosing (< 1 m) , and superior operational safety compared to batch systems.

[0025] In a further aspect, the present invention concerns the in-situ generation and use of unstable chemical compounds, in which the production of the compound and its dosing into the fluid to be treated occur simultaneously and at a distance of less than 1 meter, minimizing residence times and preventing premature decomposition. This configuration allows the direct application of the unstable chemical compound in disinfection, advanced oxidation, coagulation, neutralization, or reduction operations, ensuring maximum effectiveness and operational efficiency.

[0026] These characteristics make the system suitable to replace conventional processes based on large volumes of unstable reagents and products accumulated in tanks.

[0027] Object of the present invention is solving the aforementioned prior art problems, by providing, in a first aspect, a system for the in-situ generation of unstable chemical compounds. The system comprises a microchannel reactor installed in thermally conductive contact with a fluid to be treated, the fluid acting as a cooling medium to dissipate the heat produced by the exothermic reaction characteristic of the compound being produced. Microchannels may include internal mixing elements designed to increase turbulence and optimize reagent mixing, improving reaction efficiency and production yields of the unstable compounds generated.

[0028] In a particular configuration, the microchannel reactor is structurally integrated within a conduit flange made of highly thermally conductive materials, such as stainless steel, copper, titanium, or anodized aluminium. This flange is installed in-line with the main pipeline and allows the fluid to be treated, flowing directly in contact with the flange surfaces, to absorb the heat generated by the exothermic reaction. This arrangement ensures direct or indirect conductive cooling of the reactor and reduces the distance between the point of generation of the unstable compound and the point of contact with the fluid to less than 1 meter, substantially reducing the residence time and therefore the decomposition of the product.

[0029] The system is also equipped with an electronic control unit programmed to run machine learning algorithms, which use real-time data collected from temperature, pH, pressure, conductivity, and reagent concentration sensors. The predictive algorithm automatically adjusts operating parameters such as precursor flow rate, electrochemical current intensity, and the power of active cooling modules (e.g. , Peltier or closed-loop coolants) . In the event of critical deviations (overheating, overpressure, or accelerated product decomposition) , the control system activates intrinsic safety measures, including venting valves, stopping precursor dosing, or shutting down the reactor.

[0030] In an example of system implementation, consider the production of performic acid in a channel microreactor integrated into a stainless-steel flange. For a production rate of 1 L / h of performic acid, with a treatment rate of 100 m3 / h of wastewater and a heat dissipation power of approximately 1.075 W (3870 kJ / h) , the surface area required to effectively dissipate heat is approximately 0.036 m2. This surface area can be provided by a circular flange with a diameter of approximately 214 mm. In this case, the velocity of the fluid to be treated inside the 214 mm diameter pipe is approximately 0.771 m / s, compatible with typical velocities in wastewater treatment plants, which typically range between 0.5 and 1.5 m / s to ensure a good balance between mixing and pressure drop.

[0031] For a production rate of 10 L / h of performic acid and a treatment rate of 1000 m3 / h of wastewater, the heat output to be dissipated would increase to approximately 10.75 kW (38,700 kJ / h) . Consequently, the surface area required to dissipate this heat becomes approximately 0.358 m2, corresponding to a circular flange with a diameter of approximately 676 mm. The velocity of the fluid to be treated inside the 676 mm diameter pipe is approximately 0.774 m / s, also in line with typical sizing velocities for wastewater treatment plants. These dimensions ensure effective dissipation of the heat produced by the exothermic reaction, maintaining the system at ambient temperature and preventing accelerated decomposition of the generated chemical, while ensuring optimal flow of the fluid to be treated, compatible with standard industry practices.

[0032] This system therefore allows for effective management of the heat generated during the production of unstable chemical compounds, improving process safety and efficiency. Furthermore, using the fluid being treated as a cooling medium optimizes the use of available resources .

[0033] The system may include a connecting element between a main pipeline and the system, a reducing nozzle, an injection barrel, a flange to accommodate the micro-channels, a closing flange, a centring pin, a gasket, a heat sink and a pH sensor.

[0034] The inclusion of these components allows for optimal integration of the system into existing infrastructures, while ensuring precise control of reaction conditions and effective management of reagent and product flow.

[0035] The system can also include an additional heat sink, a Peltier cooler for active thermal control, and electrodes to integrate electrochemical reactions. The system includes intrinsic safety mechanisms based on predictive algorithms, capable of detecting anomalies such as overheating or overpressure and automatically adjusting operating conditions or shutting down the process to avoid accidents. Integrated sensors monitor key parameters in real time, providing feedback to the control system for rapid response.

[0036] The system can be configured to include photocatalytic modules that harness solar energy to power chemical production reactions, improving the system energy efficiency and reducing reliance on conventional energy sources . Additionally, energy recovery systems can be integrated to convert the exothermic heat generated into usable energy.

[0037] These additional elements allow for even finer control of the reaction temperature and the possibility of implementing electrochemical processes, expanding the application potential of the system.

[0038] The system can be configured for the production of performic acid, peracetic acid, chloramines, sodium hypochlorite or other unstable chemical compounds, with micro-channel reactor channel widths ranging from 0.01 mm to 1000 mm, preferably from 1 to 100 mm. The overall volume of the microchannels is preferably between 1% and 99% of the total volume of the reaction system, thus optimizing reagent mixing and thermal dissipation. Thus, the system can be applied in sectors requiring in-situ generation of unstable chemical compounds for water treatment, such as municipal and industrial wastewater, food and pharmaceutical production, as well as for process water management in industrial environments.

[0039] This versatility in the production of different chemical compounds makes the system suitable for a wide range of water treatment applications, while the optimised dimensions of the microchannels ensure efficient mixing and reaction of the precursors.

[0040] In addition to municipal and industrial wastewater treatment, the system is also used in food production (sanitization of pipes and CIP tanks) , the pharmaceutical industry (in-situ generation of oxidants for sterile disinfection) , process water management in complex industrial plants, and environmental disinfection of surfaces or confined spaces. The system modular and scalable capacity allows it to adapt to flow rates from a few litres per minute to over 100,000 m3 / h.

[0041] The system can be equipped with integrated physical, chemical and / or biological sensors for real-time monitoring and control of reaction conditions, using an artificial intelligence-based control system, operating in the monitored temperature range between -40 °C and 100°C and pressure from 0.1 to 10 bar. The system can also be integrated with machine learning algorithms to optimize production based on historical data and real-time operating conditions. Integration with the Internet of Things (loT) also enables remote monitoring and process optimization, ensuring greater efficiency and reliability .

[0042] The integration of advanced sensors and an Al-based control system enables continuous monitoring and real-time optimization of the process, ensuring maximum efficiency and safety under a wide range of operating conditions.

[0043] The system can be configured to reduce the distance between the point of generation of the chemical compound and the point of dosing into the fluid to be treated to a value between 0 and 10 meters, preferably less than 1 meter. The residence time of the unstable chemical between the generation point (microchannel reactor outlet) and the dosing point (contact point of the generated chemical and the treated fluid) is preferably less than 120 seconds, depending on the reduced distance between 0 and 1 meter. This time and minimum distance vary depending on the capacity of the treatment plant and could vary up to 1200 seconds and 10 meters for large plants. This configuration minimizes the residence time of the unstable chemical before its use, significantly reducing decomposition and increasing treatment effectiveness.

[0044] Furthermore, in another configuration, the system flange can be mounted between two turbomachines connected in series, allowing the release of the generated chemical under controlled pressure conditions, ranging from 0.1 to 10 bar (absolute pressure) , preferably between 0.45 and 4.5 bar (absolute pressure) . This configuration promotes a high level of mixing and allows for the immediate dispersion and reaction of the chemical with the fluid being treated. Installation between turbomachines ensures homogeneous distribution of the product and maximizes its effectiveness in water treatment applications or critical industrial processes.

[0045] The micro-channel reactor can be machined and / or integrated into a pipe flange, allowing for modularity and scalability of generator production by connecting them in series or in parallel, for treatment flow rates ranging from 1 m3 / h to 100,000 m3 / h.

[0046] The system modularity and scalability make it suitable for a wide range of applications, from small installations to large industrial plants, ensuring flexibility and adaptability to different treatment needs. The ratio between the flow rate of the treated fluid and the heat exchange surface of the system is preferably between 100 and 10000 m3 / h / m2, preferably from 1000 to 3000 m3 / h / m2.

[0047] The microchannel reactor can be configured with electrodes to enable electrochemical reaction intensification processes by applying a current between 0.01 A and 100 A (preferably between 0.1 A and 10 A) , and a potential difference between 0.1 V and 1000 V (preferably between 1 V and 100 V) .

[0048] The integration of electrochemical processes offers further possibilities for optimizing and intensifying reactions, increasing the overall efficiency of the system and expanding its potential applications .

[0049] In a second aspect, a method for the in-situ production of unstable chemical compounds is envisaged. The method comprises the following steps: a) mixing chemical precursors in a microchannel reactor; b) dissipation of the heat produced by the exothermic reaction via the fluid to be treated, used as a cooling medium, in direct or indirect conductive contact with the generator; c) control of the production process via integrated sensors and an artificial intelligence-based control system.

[0050] This method effectively integrates the production of unstable chemical compounds with the fluid treatment process, optimizing resource use and ensuring precise control of reaction conditions.

[0051] The method may involve the production of performic acid, peracetic acid, chloramines, or sodium hypochlorite, with a controlled reaction temperature between 0.1°C and 100°C, and a dissipated thermal power between 1 W and 1000 W. This power scales proportionally with the mass quantities of performic acid to be generated. For example, for a production of 1 L / h of performic acid, the thermal power to be dissipated is approximately 1.075 W (3870 kJ / h) . For a production of 10 L / h of performic acid, the thermal power to be dissipated increases to approximately 10.75 kW (38700 kJ / h) . This versatility in producing different chemical compounds, combined with precise control of temperature and heat dissipation, makes the method suitable for a wide range of water treatment applications, while ensuring process efficiency and safety.

[0052] The above and other objects and advantages of the invention, as will become apparent from the following description, are achieved with a system and method for the in-situ generation of unstable chemical compounds such as those described in the respective independent claims. Preferred embodiments and non-trivial variations of the present invention form the subject of the dependent claims.

[0053] It is understood that all attached claims form an integral part of this specification.

[0054] The present invention will be better described by some preferred embodiments, provided by way of example and not by way of limitation, with reference to the attached drawings, in which:

[0055] FIG. 1 shows an exploded perspective view of the main configuration of the access control system.

[0056] FIG. 2 shows a block diagram of the access control system, with sections AA and DD to highlight the internal components.

[0057] FIG. 3 shows a front view of the control device with details of the flange micro-channels. FIG. 4 shows an alternative exploded side view of the system, showing injection barrel and structural components.

[0058] FIG. 5 shows a series configuration of the system with microchannel reactor modules and Peltier coolers.

[0059] FIG. 6 shows an alternative configuration with sharing of mixing flanges and gaskets between the modules.

[0060] FIG. 7 shows an alternative fully assembled configuration with compact mixing and thermal control modules.

[0061] With reference to the Figures, a preferred embodiment of the present invention is illustrated and described. It will be immediately obvious that countless variations and modifications (for example, relating to shape, dimensions, various colours, and parts with equivalent functionality) may be made to the description without departing from the scope of the invention as claimed in the appended claims .

[0062] The present invention relates to an advanced system for the in- situ generation of unstable chemical compounds, such as performic acid, peracetic acid, sodium hypochlorite, or chloramines. This system, designed with a modular and scalable architecture, integrates a microchannel reactor in thermally conductive contact with the fluid being treated, using the fluid itself as a cooling medium to effectively dissipate the heat produced by the exothermic reactions that form the chemical compounds. This optimized heat management not only improves process safety but also increases the yield of the chemical compounds produced, reducing the risk of accelerated decomposition due to localized overheating.

[0063] Furthermore, the system minimizes the distance between the chemical generation point and the point of dosing into the fluid being treated, thus reducing the compound residence time before use and limiting spontaneous decomposition of the product. This aspect is particularly important for unstable chemical compounds, whose effectiveness can be compromised by premature decomposition.

[0064] Another advantage of the proposed system is the precise, realtime control of reaction conditions. The system is equipped with integrated physical, chemical, and / or biological sensors that constantly monitor key parameters such as temperature, pressure, pH, and reagent concentration. This data is sent to an Al-based control system, which uses advanced algorithms to optimize operating conditions in real time, ensuring maximum process efficiency and safety .

[0065] Therefore, the system described is configured to integrate a series of physical, chemical, and biological sensors to monitor and optimize operating conditions in real time. Physical sensors include temperature, pressure, flow, and level sensors to ensure precise process control, as well as thermal conductivity and vibration sensors to monitor system stability. Chemical sensors monitor key parameters such as pH, dissolved oxygen concentration, conductivity, redox potential (ORP) , and the concentration of reagents such as formic acid and hydrogen peroxide. Finally, biological sensors, such as biosensors for the detection of sulf ate-reducing bacteria, ATP, COD, and sulfide sensors, allow monitoring of biological activity and the presence of organic contaminants. These sensors, integrated into the system, provide real-time data to an Al-based control system, optimizing the generation of unstable chemical compounds and improving overall treatment efficiency.

[0066] In summary, the proposed system offers an innovative solution for the in-situ generation of unstable chemical compounds, overcoming several limitations of conventional methods and offering significant improvements in terms of heat management, decomposition control, and real-time monitoring of reaction conditions.

[0067] Referring to FIG. 1, an exploded isometric view of the main system configuration is shown. The system comprises a connecting element, preferably a 1-1 / 4" NPT threaded nipple (1) , which forms the connecting element between the main piping and the system, ensuring continuous fluid flow into the reactor. The various components are fastened together by means of l / 2"-13 UNC hex bolts (2) , which, together with the flat washers (3) , evenly distribute the clamping pressure, avoiding damage to the surrounding surfaces. The system incorporates a 2-1 / 2" NPT to 1-1 / 4" NPT reducer fitting (4) , which allows connection between tubing of different diameters, reducing the diameter from the main tubing to the mixing component. The injection barrel (5) allows for precise injection of reagent into the fluid, and the 2-1 / 2" flange (6) houses the microchannels necessary for mixing reagents.

[0068] To correctly align the parts, a centring pin (7) is used, which ensures precise positioning during assembly. To avoid fluid leaks, a PTFE gasket (8) perfectly seals the interface between the two flanges (6) and (10) , while the heat sink (9) takes care of dissipating the thermal energy generated by the exothermic reactions.

[0069] The flange (10) closes the system, completing the fluid mixing process within the micro-channels. Smaller l / 4"-28 UNF hex bolts (11) are used to securely fasten minor components such as sensors and seals. Lock washers (12) help prevent bolts from loosening due to vibration, while the pH sensor (13) continuously monitors the fluid chemical conditions to maintain optimal reaction parameters. Finally, hex nuts (14) securely lock the bolts (2) , ensuring all components remain tight, while another reducer (15) allows connection to larger diameter tubing, and the 1-1 / 2" threaded nipple (16) completes the final connection of the system.

[0070] In some cases, the system can be configured to handle variable flow rates, adapting to the customer treatment needs. The integration of Al-based control would optimize performic acid production efficiency, reducing consumption by up to 50% compared to conventional systems. Furthermore, advanced heat management prevented accelerated product decomposition, ensuring process continuity at all times under high-performance conditions. In one implementation example, the system was installed in a wastewater treatment plant with a flow rate of 5,000 m3 / h. Thanks to the short distance between the chemical generation point and the dosing point (less than 1 meter) , and advanced thermal control, a 30% increase in efficiency was achieved, with a 40% reduction in chemical consumption compared to conventional systems.

[0071] Referring to FIG. 2, several cross-sections (AA and DD) and perspective views of the system are shown, highlighting the internal components and their integrated functionality for fluid mixing and heat management. The 1-1 / 4" NPT threaded nipple (1) ensures fluid passage through the system, while the 1 / 2" hex bolts (2) , combined with the flat washers (3) , secure the flanges together, forming the main structure of the system.

[0072] The flange (6) , with its internal micro-channels, is responsible for the continuous mixing of the reagents, and the PTFE gasket (8) ensures a hermetic seal to prevent leaks. The heat sink (9) , positioned between the flanges, is essential for maintaining safe temperatures by dissipating the heat produced by the reactions. The flange (10) completes the mixing system, sealing the micro-channels and ensuring that the fluid passes through the system without interruption .

[0073] In some cases, the system may include a heat sink (17) , which helps maintain temperature, and a Peltier cooler (18) for active thermal control, powered by the positive (19) and negative (20) leads. Electrodes (21 and 22) are strategically placed to maintain control of electrochemical reactions throughout the system.

[0074] In some designs, internal parts, such as the mixing flanges (23) and gaskets (24 and 25) , can be shared between multiple modules to facilitate uniform fluid distribution and prevent leaks. This modular configuration allows for easy maintenance and reduces downtime.

[0075] Furthermore, the system can be configured to handle variable flow rates, adapting to the customer treatment needs. The integration of Al-based control would optimize performic acid production efficiency, reducing consumption by up to 50% compared to conventional systems. Furthermore, advanced heat management has prevented accelerated product decomposition, ensuring process continuity at all times under high-performance conditions.

[0076] Referring to FIG. 3, a cross-section of the flange (6) is illustrated showing the internal details of the micro-channels. The micro-channels are designed to guide the fluid flow through a precise path, facilitating optimal mixing of the reagents. In some cases, the micro-channels can have a width ranging from 0.01 mm to 100 mm, depending on the specific needs of the chemical process and operating conditions. This micro-channel configuration allows for efficient heat management, improving both process safety and the yield of the chemical produced. The ratio of the micro-channel diameter to the channel length is preferably between 1:5 and 1:500 (preferably 1:10 and 1:100) , ensuring optimal control of reagent flow and heat dissipation. Furthermore, the optimized arrangement of the microchannels inside the flange (6) helps reducing the distance between the point of generation of the chemical compound and the point of dosing into the fluid to be treated, thus limiting the spontaneous decomposition of the product and optimizing the effectiveness of the chemical compound.

[0077] Referring to FIG. 4, an alternative exploded isometric configuration of the system is shown. In this configuration, the system includes an injection barrel (5) for precise injection of the reagent into the fluid. Flanges (6 and 10) provide structural support and contain the micro-channels for mixing the reagents.

[0078] In some cases, the system may include a heat sink (17) , which helps maintain temperature, and a Peltier cooler (18) for active thermal control, powered by the positive (19) and negative (20) leads. Electrodes (21 and 22) are strategically placed to maintain control of electrochemical reactions throughout the system. In this configuration, the system can be configured to handle variable flow rates, adapting to the customer treatment needs. The integration of Al-based control would optimize performic acid production efficiency, reducing consumption by up to 50% compared to conventional systems. Furthermore, advanced heat management has prevented accelerated product decomposition, ensuring process continuity at all times under high-performance conditions.

[0079] Referring to FIG. 5, the series configuration of the alternative configuration shown in FIG. 4 is illustrated. In this configuration, the system comprises a series of modules, each of which includes an injection barrel (5) , flanges (6 and 10) , a heat sink (17) , and a Peltier cooler (18) . Electrodes (21 and 22) are strategically placed in each module to maintain control of the electrochemical reactions throughout the system.

[0080] In some cases, modules can be connected in series to handle variable treatment flow rates, adapting to the customer specific needs. For example, for a water treatment plant with a flow rate of 10 m3 / h, ten modules can be connected in series, each designed to handle a flow rate of 1 m3 / h. This series configuration optimizes chemical production efficiency, reducing chemical consumption by up to 50% compared to conventional systems.

[0081] Furthermore, the advanced heat management, ensured by the presence of the heat sink (17) and the Peltier cooler (18) in each module, prevents accelerated product decomposition phenomena, ensuring process continuity always under high performance conditions. In particular, the Peltier cooler (18) , powered by the positive (19) and negative (20) conductors, provides active thermal control, regulating the temperature of the micro-channel reactor according to the specific needs of the chemical process.

[0082] Electrodes (21 and 22) , strategically positioned in each module, allow for the integration of electrochemical reactions into the system by applying a controlled current to optimize the chemical reactions. This electrochemical configuration may be particularly advantageous for the production of chemical compounds that require specific reaction conditions, such as performic acid.

[0083] In conclusion, the array configuration illustrated in FIG. 5 offers a flexible and scalable solution for the in-situ generation of unstable chemical compounds, overcoming several limitations of conventional methods and offering significant improvements in terms of heat management, decomposition control, and real-time monitoring of reaction conditions.

[0084] Referring to FIG. 6, an alternative system configuration is illustrated, where internal parts, such as the mixing flanges (23) and gaskets (24 and 25) , are shared between multiple modules. This configuration helps to facilitate uniform fluid distribution and prevent leaks. In particular, the mixing flanges (23) are designed to guide the fluid flow through a precise path, facilitating optimal mixing of the reagents. The gaskets (24 and 25) , positioned between the mixing flanges (23) , ensure a hermetic seal to prevent fluid leaks .

[0085] In some cases, the configuration can be designed to handle variable flow rates, adapting to the customer treatment needs. For example, for a water treatment plant with a flow rate of 10 m3 / h, ten modules can be connected in series, each designed to handle a flow rate of 1 m3 / h. This series configuration optimizes chemical production efficiency, reducing chemical consumption by up to 50% compared to conventional systems.

[0086] Furthermore, the advanced heat management, ensured by the presence of the heat sink (17) and the Peltier cooler (18) in each module, prevents accelerated product decomposition phenomena, ensuring process continuity always under high performance conditions. In particular, the Peltier cooler (18) , powered by the positive (19) and negative (20) conductors, provides active thermal control, regulating the temperature of the micro-channel reactor according to the specific needs of the chemical process.

[0087] Electrodes (21 and 22) , strategically positioned in each module, allow for the integration of electrochemical reactions into the system by applying a controlled current to optimize the chemical reactions. This electrochemical configuration may be particularly advantageous for the production of chemical compounds that require specific reaction conditions, such as performic acid.

[0088] In conclusion, the alternative configuration illustrated in FIG. 6 offers a flexible and scalable solution for the in-situ generation of unstable chemical compounds, overcoming several limitations of conventional methods and offering significant improvements in terms of heat management, decomposition control, and real-time monitoring of reaction conditions.

[0089] Referring to FIG. 7, the alternative configuration described in FIG. 6 is shown fully assembled. In this configuration, the mixing flanges (23) and the injection barrels (5) are integrated into a single compact module, ensuring efficient fluid flow and optimal mixing of the reagents. The gaskets (24 and 25) , positioned between the mixing flanges (23) , ensure a hermetic seal to prevent fluid leaks .

[0090] In some cases, the system can be configured to handle variable flow rates, adapting to the customer treatment needs. For example, for a water treatment plant with a flow rate of 10 m3 / h, ten modules can be connected in series, each designed to handle a flow rate of 1 m3 / h. This series configuration optimizes chemical production efficiency, reducing chemical consumption by up to 50% compared to conventional systems. Furthermore, the advanced heat management, ensured by the presence of the heat sink (17) and the Peltier cooler (18) in each module, prevents accelerated product decomposition phenomena, ensuring process continuity always under high performance conditions. In particular, the Peltier cooler (18) , powered by the positive conductors (19) and the negative conductors (20) , provides active thermal control, regulating the temperature of the micro-channel reactor according to the specific needs of the chemical process.

[0091] Electrodes (21 and 22) , strategically positioned in each module, allow for the integration of electrochemical reactions into the system by applying a controlled current to optimize the chemical reactions. This electrochemical configuration may be particularly advantageous for the production of chemical compounds that require specific reaction conditions, such as performic acid.

[0092] In conclusion, the alternative configuration illustrated in FIG. 7 offers a flexible and scalable solution for the in-situ generation of unstable chemical compounds, overcoming several limitations of conventional methods and offering significant improvements in terms of heat management, decomposition control, and real-time monitoring of reaction conditions.

[0093] In some cases, the system may incorporate additional advanced features to improve performance, efficiency, and operational safety. For example, the system may include advanced heat exchangers made from high thermal conductivity materials to improve heat dissipation. These heat exchangers can be integrated along the walls of the microchannel reactor or into the modular flanges, ensuring efficient heat management. The flanges and microchannels can be made from high thermal conductivity materials such as anodized aluminium, titanium, or advanced composite materials such as graphene to improve heat dissipation. For highly corrosive applications, PTFE or fluorinated polymer coatings can be used to ensure thermal and chemical resistance .

[0094] Additionally, the system can utilize advanced refrigerants, such as nanofluids, to increase heat transfer capacity. These advanced refrigerants can further reduce the risk of system overheating, improving the stability of chemical reactions and preventing premature decomposition of the produced chemical compounds.

[0095] To ensure maximum effectiveness of the in-situ generated chemicals, the system can incorporate stability monitoring devices, such as performic acid, and apply decomposition inhibitors when necessary. These inhibitors can be introduced in a controlled manner to extend the lifetime of the compounds, ensuring greater water treatment efficiency and reducing the need for repeated production.

[0096] The system can also include safety sensors to detect temperature spikes, overpressures, and abnormal changes in fluid composition. If abnormal conditions are detected, the Al control system can automatically intervene by adjusting operating parameters or, if necessary, shutting down the process to prevent damage or accidents. This intrinsic safety is essential in industrial operations, where the reaction between precursors can generate significant heat.

[0097] In some cases, the system can utilize high-resistance microchannel pathways, such as those found in Tesla valves, to improve reaction control and system efficiency. These high-resistance microchannel pathways can optimize reagent mixing and heat management, improving the yield of the chemicals produced.

[0098] Microchannels within flanges can be created using various advanced manufacturing techniques. For example, precision laser cutting techniques can be used to create intricate paths within the flanges. Alternatively, chemical or plasma etching techniques can be used to form microchannels with high precision. Other techniques may include CNC milling to sculpt the microchannels into the flange material, 3D printing to manufacture flanges with integrated microchannels, or casting, using specially designed moulds to form the microchannels during the manufacturing process. Using these techniques ensures high precision and consistent quality in flanges with microchannels.

[0099] The system is designed to operate at fluid temperatures ranging from -40°C to 100°C, depending on the chemical reaction and environmental conditions. For industrial applications with low- freezing fluids, the system can also operate at negative process temperatures, down to -40°C. This flexibility in operating conditions allows the system to adapt to a wide range of industrial applications, ensuring efficient and safe operation under all conditions .

[0100] The system integrates advanced control algorithms based on artificial intelligence (Al) to optimize the generator reaction conditions. These algorithms may include physically informed neural networks and deep learning techniques, which use sensor data to predict reaction progression and optimize operating parameters. For example, Al can reduce the energy required for cooling by dynamically adjusting fluid flow or reagent dosing based on system demand and environmental conditions. This approach allows for significant energy savings and greater process stability, avoiding thermal or chemical fluctuations .

[0101] The microchannel reactor is designed to be modular, allowing multiple units to be connected in series or in parallel to handle different treatment flow rates. Each module can be equipped with a heat sink to remove excess heat and a Peltier cooler to maintain optimal operating temperatures. This modular design allows for linear scalability from small to large industrial plants, with flexible configuration depending on customer needs. Each microreactor can handle flow rates ranging from 0.01 L / min to 1000 L / min, providing scalable production options for various industrial applications. Some preferred embodiments of the present invention have been illustrated and described above: obviously, numerous variants and modifications, functionally equivalent to the previous ones, will be immediately evident to those skilled in the art, which fall within the scope of the invention as highlighted in the appended claims.

Claims

CLAIMS1. System for the in-situ generation of unstable chemical compounds, comprising a microchannel reactor structurally integrated into a flange of conductive material and installed in conductive thermal contact with a fluid to be treated, the reactor being in direct or indirect conductive thermal contact with the fluid to be treated flowing through the piping and acting as a cooling medium to dissipate the heat generated by an exothermic reaction, the system being configured such that the distance between an outlet point of a reactor producing the unstable chemical compound and a point of contact of the unstable chemical compound with the fluid to be treated is small, preferably less than 0.1 m.

2. System according to claim 1, wherein the flange is compatible with industrial connection standards and designed to handle flow rates between 1 m3 / h and 100, 000 m3 / h, in a single or modular configuration .

3. System according to any preceding claim, wherein the term"unstable chemical compound" means a compound or mixture whose concentration decreases by spontaneous decomposition at a rate greater than 0.1 mg / L per day, preferably greater than 1 mg / L per day, under standard ambient conditions (20-25 °C, atmospheric pressure) .

4. System according to any of the preceding claims, wherein the internal micro-channels have shaped geometries or internal structures suitable for generating turbulence and improving the mixing of the reactants and heat exchange.

5. System according to any of the preceding claims, wherein the reactor is further coupled to a passive or active heat sink, selected from: finned heat sink, heat exchanger, Peltier module or coolant circuit.

6. System according to any of the preceding claims, comprising at least one pair of conductive electrodes configured to promote or intensify electrochemical reactions, with current between 0.01 A and 100 A and potential between 0.1 V and 1000 V.

7. System according to any of the preceding claims, comprising one or more physical, chemical and / or biological sensors for monitoring parameters selected from: temperature, pH, conductivity, concentration, pressure.

8. System according to claim 7, wherein the sensors are connected to an automatic or artificial intelligence-based control system, programmed to adjust at least one operating parameter of the reactor in real time.

9. System according to any of the preceding claims, wherein the reactor comprises at least one homogeneous or heterogeneouscatalyst selected from acid basic metal or enzymatic catalysts, to promote the chemical reaction.

10. System according to claim 9, wherein the acidic heterogeneous catalyst is selected from: acidic ion exchange resins, namely Amberlyst®, Dowex®, Nafion®, acidic zeolites, namely ZSM-5, Beta, Y, sulfated zirconia or modified titania, hydrated niobia or niobium phosphate, carbons functionalized with sulfonic groups, namel -SO3H, silica-anchored supported heteropolyacids, MCM-41 or activated carbons.

11. System according to any of the preceding claims, wherein the catalyst is applied by coating, namely "wash-coat", the internal walls of the micro-channels, deposition on monolithic supports or insertion of impregnated granular particulate.

12. System according to any of the preceding claims, wherein the catalytic material performs a dual function: (i) providing Bronsted or Lewis acid sites for the per-acidif ication reaction, and (ii) modulating the presence of water by adsorption or selective confinement, in order to increase the yield of performic acid.

13. System according to any preceding claim, wherein the reactor is configured to maintain the residence time of the reactants in a range between 1 and 10 seconds, at temperaturesbelow 50 °C, so as to maximize the stability of the unstable compound produced.

14. System according to any of the preceding claims, wherein the residence time of the reactants in the microchannel reactor is less than 600 seconds, preferably between 1 and 120 seconds.

15. System according to any of the preceding claims, wherein the chemical precursors introduced into the microchannel reactor are selected from gaseous, liquid or solid phase fluids, or gasliquid, gas-solid, liquid-solid or gas-liquid-solid multiphase combinations .

16. System according to any of the preceding claims, wherein the reaction temperature is maintained below 70 °C, preferably below 50 °C.

17. System according to any of the preceding claims, wherein the microchannels of the reactor have dimensions between 0.01 mm and 1000 mm, preferably between 0.01 mm and 100 mm.

18. System according to any of the preceding claims, wherein the unstable chemical compound produced is selected from: performic acid (PFA) , peracetic acid (PAA) , chloramines, sodium hypochlorite or combinations thereof .

19. System according to any of the preceding claims, wherein the unstable chemical compound produced is selected from: Caro's acid (H2SOs) , perpropionic, perbutyric and perbenzoic acids,chlorine dioxide (C102) , hydrogen peroxide (H2O2), ozone (03), sodium hypobromite (NaOBr) , sodium chlorite (NaC102) , potassium permanganate (KMnO4) , bromine (Br2), iodamines and iodine oxidizing species (I2, HIO) , hydroxyl radicals (»0H) , sulfate radicals ( S04*-), halogenated radicals (Cl*, Br»), hydrate - electron radicals (eaq“) , reducing species such as sulfur dioxide (SO2), sulfite (Na2SO3) , bisulfite (NaHSOa), iron(II) , molecular hydrogen (H2) , as well as strong acids and bases generated in situ (H2SO4, HNOa, HC1, NaOH, KOH) or coagulants (FeCl3, A12(SO4)3, CaCl2, MgCl2) .

20. System according to any of the preceding claims, wherein the performic acid is generated in situ and dosed directly into the fluid to be treated in concentrations between 0.01% and 10% w / w, without the need for storage or accumulation in separate tanks .

21. System according to any of the preceding claims, wherein the mechanical components of the system are configured to be modular, interchangeable and installable in series or in parallel with other similar systems.

22. Method for the in-situ generation of an unstable chemical compound within a pipeline containing a fluid to be treated, comprising the following steps:a) mixing of chemical precursors within a microchannel reactor integrated into a flange installed inline on the pipeline; b) dissipation of the heat generated by the reaction through conductive thermal contact with the fluid being treated; c) direct dosing of the unstable chemical compound generated into the fluid itself, at a distance of less than one meter from the point of generation; d) monitoring and automatic adjustment of process parameters via integrated sensors and a control system, preferably based on artificial intelligence.

23. Method according to claim 22, wherein the unstable chemical compound is selected from performic acid, peracetic acid, chloramines or sodium hypochlorite, and wherein the reaction takes place in channels with dimensions between 0.01 mm and 100 mm, with a controlled temperature between 0.1 °C and 100 °C.

24. Method according to any of claims 22-23, wherein the chemical precursors are provided in gaseous, liquid or solid phase, or in gas-liquid, gas-solid, liquid-solid or gas-liquid- solid multiphase combinations.

25. Method according to any of claims 22-24, wherein the heterogeneous catalysis is achieved by acid resins, zeolites, sulfated zirconia, niobium or heteropolyacids supported, coated or anchored to the walls of the microchannels.

26. Method according to any of claims 22-25, wherein the yield of performic acid is promoted by selective adsorption of the reaction water on microporous or mesoporous materials integrated in the channel, reducing the equilibrium shift towards the reactants .

27. Use of a system for the in-situ generation of unstable chemical compounds, comprising a micro-channel reactor integrated into a conductive flange and installed in thermal contact with a fluid to be treated, in which the generation and use of the compound occur simultaneously and at a distance of less than 1 m between the point of production and the point of dosing, in order to reduce premature decomposition of the compound itself.

28. Use according to claim 27, wherein the unstable chemical compound is selected from peracids, inorganic oxidants, radicals, reductants, strong acids and bases generated in situ, or coagulants according to the preceding claims, and is used for disinfection, advanced oxidation, reduction, coagulation, neutralization, treatment of municipal or industrial water, environmental disinfection or sanitization of food or pharmaceutical plants.

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