High flow rate heat exchange apparatus for continuous flow reactors and flow reactor modules comprising the same

Abstract

A heat exchange apparatus comprises a body, a plurality of ribs, and at least two ports. The body has an interior surface that defines a cavity opening to a first side of the body. The ribs extend from the interior surface and are arranged in multiple rows that are spaced in a first direction. The at least two ports open to the cavity through the interior surface. The ribs are elongate in a second direction that is orthogonal to the first direction. The ribs within each row are spaced from one another in the second direction so as to define a gap between adjacent ribs. The ribs within each successive row are offset along the second direction relative to the ribs within a preceding row such that most of the gaps in the preceding row, when projected in the first direction, intersect a respective rib in the successive row.

Description

SP25-013HIGH FLOW RATE HEAT EXCHANGE APPARATUS FOR CONTINUOUS FLOW REACTORS AND FLOW REACTOR MODULES COMPRISING THE SAMECROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority of France Patent Application Serial No. 2500793 filed on January 24, 2025, and claims the benefit of priority of U.S. Provisional Application Serial No. 63 / 749112 filed on January 24, 2025, the content of which is relied upon and incorporated herein by reference in its entirety.FIELD

[0002] The present disclosure relates to apparatuses for continuous flow reactors and flow reaction processing. In particular, the present disclosure relates to heat exchange apparatuses that comprise patterns of features or protuberances configured to improve thermal performance factor.BACKGROUND

[0003] High performance process fluid modules for continuous flow reactors may benefit from or require thermal control of the reaction processes that occur therein. One solution to provide such thermal control includes use of a generally planar process fluid module 10, as shown in FIG. 13, and heat exchange enclosures 16, 18, as shown in FIG. 14. The process fluid module 10 can comprise a body that has two major outer surfaces 12, 14 and contains a process fluid passage P disposed within the body. The heat exchange enclosures 16, 18 can be sealed to the major outer surfaces 12, 14 so as to define a heat exchange fluid passage HP in contact with the major outer surface 12, 14. Small protuberances or “turbulators” (not shown) on an interior surface of the heat exchange enclosures have been used to increase turbulence and / or secondary flows in heat exchange fluid that flows through the heat exchange fluid passages HP.

[0004] In some cases, existing configurations of the protuberances may not provide sufficient thermal performance factor (e.g., heat extraction to pressure drop ratio). Consequently, it would be advantageous to provide new configurations of the protuberances configured to facilitate both lateral flow for flow redistribution and crosswise flow through a flow constriction to locally increase Nusselt number and, therefore, better agitate the heat exchange fluid.SP25-013SUMMARY

[0005] The following summary is a brief description of certain aspects of the present disclosure. The summary should not be considered as limiting of the breadth, scope, or applicability of the present disclosure.

[0006] According to a first aspect, a heat exchange apparatus is provided. The heat exchange apparatus comprises: a body having an interior surface configured to define a cavity that opens to a first side of the body; a plurality of ribs extending from the interior surface, the ribs arranged in multiple rows that are spaced from one another in a first direction ; and at least two ports opening to the cavity through the interior surface, the at least two ports spaced from one another in the first direction, wherein the ribs are elongate in a second direction that is orthogonal to the first direction, the ribs within each row being spaced from one another in the second direction so as to define a gap between adjacent ribs, and wherein the ribs within each successive row are offset along the second direction relative to the ribs within a preceding row such that most of the gaps in the preceding row, when projected in the first direction, intersect a respective rib in the successive row.

[0007] According to a second aspect, a flow reactor module is provided. The flow reactor comprises: a first process fluid module with a process fluid passage extending therethrough, the first process fluid module comprising an extended body having a width, a length, and a thickness that is less than the width and less than the length, the first process fluid module having a first major surface and a second major surface disposed on opposite sides of the first process fluid module; a first heat exchange apparatus sealed against the first major surface of the first process fluid module, the first heat exchange apparatus comprising: a body having a first side with an interior surface that defines a cavity configured to contain heat exchange fluid against the first major surface of the first process fluid module, a plurality of ribs extending from the interior surface to define a heat exchange fluid path for the heat exchange fluid, the ribs arranged in multiple rows that are spaced from one another in a first direction, at least one inflow port extending through the body and opening to the cavity through the interior surface, the at least one inflow port configured to deliver the heat exchange fluid to the heat exchange fluid path, and at least one outflow port extending through the body and opening to the cavity through the interior surface, the at least one outflow port configured to receive the heat exchange fluid from the heat exchange fluid path, the at least one outflow port spaced from the at least one inflow port in the first direction, wherein the ribs are elongate in a second direction that is orthogonal to the first direction, the ribs within each row being spaced from one anotherSP25-013in the second direction so as to define a gap between adjacent ribs, and wherein the ribs within each successive row are offset along the second direction relative to the ribs within a preceding row such that most of the gaps in the preceding row, when projected in the first direction, intersect a respective rib in the successive row.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Various exemplary embodiments of the present disclosure are described in detail below with reference to the following drawings. The drawings are provided for purposes of illustration only and merely depict exemplary embodiments of the present disclosure to facilitate the understanding of the present disclosure. Therefore, the drawings should not be considered as limiting of the breadth, scope, or applicability of the present disclosure. It should be noted that for clarity and ease of illustration these drawings are not necessarily drawn to scale.

[0009] FIG. 1 is a perspective view of a heat exchange apparatus comprising a plurality of ribs according to embodiments of the present disclosure;

[0010] FIG. 2 is a plan view of the heat exchange apparatus of FIG. 1 ;

[0011] FIG. 3 is a detail view of a portion of the heat exchange apparatus of FIG. 1 with the portion sectioned along a plane to illustrate aspects of the ribs;

[0012] FIG. 4 is a detail view of a portion of the heat exchange apparatus of FIG. 2 showing further aspects of the ribs;

[0013] FIGS. 5 A and 5B are detail views of the same portion of the heat exchange apparatus of FIG. 4 illustrating one of a plurality of mixing units formed by the ribs;

[0014] FIG. 6 is a perspective view of a flow reactor module comprising the heat exchange apparatus of FIG. 1 connected to a process fluid module according to embodiments of the present disclosure;

[0015] FIG. 7 is a schematic cross section through a portion of the flow reactor module of FIG. 6 showing further aspects of the ribs;

[0016] FIG. 8 is a series of plan views of a heat exchange apparatus comprising a first plurality of ribs and a second plurality of ribs on opposites sides of the heat exchange apparatus according to embodiments of the present disclosure;SP25-013

[0017] FIG. 9 is a diagram illustrating flow velocity magnitude of a crosswise flow of the heat exchange fluid through a clearance between a rib and an external surface from a simulation according to the Example;

[0018] FIG. 10 is a diagram illustrating flow velocity magnitude of a flow of the heat exchange fluid through the heat exchange apparatus of FIG. 1 along a first plane depicted in FIG. 8 from the simulation according to the Example;

[0019] FIG. 11 is a diagram illustrating flow velocity magnitude of a flow of the heat exchange fluid through the heat exchange apparatus of FIG. 1 along a second plane depicted in FIG. 8 from the simulation according to the Example;

[0020] FIG. 12 is a detail view of a portion of the diagram of FIG. 10 showing further aspects of the flow velocity magnitude;

[0021] FIG. 13 is a diagrammatic perspective view of a process fluid module;

[0022] FIG. 14 is a diagrammatic elevational view of a fluidic module including a process fluid module and heat exchange enclosures; and

[0023] FIG. 15 is a perspective view showing a process fluid module with detail of an embodiment of an (interior) process fluid passage.DETAILED DESCRIPTION

[0024] For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the disclosure is thereby intended. It is further understood that the present disclosure includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles disclosed herein as would normally occur to one skilled in the art to which this disclosure pertains.

[0025] As used herein, the term “and / or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and / or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.SP25-013

[0026] In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0027] As used herein, the term “about” means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and / or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. When the term “about” is used in describing a value or an end-point of a range, the disclosure should be understood to include the specific value or end-point referred to. Whether or not a numerical value or end-point of a range in the specification recites “about,” the numerical value or end-point of a range is intended to include two embodiments: one modified by “about,” and one not modified by “about.” It will be further understood that the end-points of each of the ranges are significant both in relation to the other end-point, and independently of the other end-point.

[0028] Concentrations, amounts, and other numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range was explicitly recited. As an illustration, a numerical range of “about 1 to about 5” should be interpreted to include not only the explicitly recited values of about 1 to about 5, but also to include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 2, 3, and 4, the sub ranges such as from 1-3, from 2-4, from 3-5, etc., as well as 1, 2, 3, 4, and 5 individually. The same principle applies to ranges reciting only one numerical value as a minimum or maximum. Furthermore, such an interpretation should apply regardless of the breadth of the range or the characteristics being described by the range.

[0029] The terms “substantial,” “substantially,” and variations thereof as used herein, unless defined elsewhere in association with specific terms or phrases, are intended to note that a described feature is equal or approximately equal to a value or description. For example, a “substantially planar” surface is intended to denote a surface that is planar or approximately planar. Moreover, “substantially” is intended to denote that two values are equal orSP25-013approximately equal. In some embodiments, “substantially” may denote values within about 10% of each other, such as within about 5% of each other, or within about 2% of each other.

[0030] Directional terms as used herein — for example up, down, right, left, front, back, top, bottom, above, below, and the like — are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0031] As used herein the terms "the," "a," or "an," mean "at least one," and should not be limited to "only one" unless explicitly indicated to the contrary. Thus, for example, reference to "a component" includes embodiments having two or more such components unless the context clearly indicates otherwise.

[0032] FIGS. 1-7 illustrate aspects of a heat exchange apparatus 100 according to embodiments of the present disclosure. FIG. 1 is a perspective view of the heat exchange apparatus comprising a plurality of ribs according to embodiments of the present disclosure. FIG. 2 is a plan view of the heat exchange apparatus 100. FIG. 3 is a detail view of a portion of the heat exchange apparatus 100 (e.g., indicated by region 3 in FIG. 1) with the portion sectioned along a plane to illustrate aspects of the ribs. FIG. 4 is a detail view of a portion of the heat exchange apparatus 100 (e.g., indicated by region 4 in FIG. 2) showing further aspects of the ribs. FIGS . 5 A and 5B are detail views of the same portion of the heat exchange apparatus 100 (e.g., indicated by region 5 in FIG. 4) illustrating one of a plurality of mixing units formed by the ribs. FIG. 6 is a perspective view of a flow reactor module 200 comprising the heat exchange apparatus 100 connected to a process fluid module 10 according to embodiments of the present disclosure. FIG. 7 is a schematic cross section through a portion of the flow reactor module 200 showing further aspects of the ribs.

[0033] As shown in FIGS. 1-7, the heat exchange apparatus 100 comprises a body 104 that has an interior surface 108 configured to define a cavity 112 (FIG. 7) on a first side 116 of the body. When the heat exchange apparatus 100 is not sealed or otherwise attached to a separate component (e.g., the process fluid module 10 discussed later in this disclosure), the cavity 112 opens to the first side 116 of the body 104, as shown in FIGS. 1-3. The body 104 can be formed from any material and can have any general shape that enables the heat exchange apparatus 100 to have the attributes described throughout this disclosure. In an exemplary embodiment, the body 104 has a plate-like shape comprising a length L, a width W, and a thickness T that is less than the length L and less than the width W.SP25-013

[0034] The heat exchange apparatus 100 further comprises a plurality of ribs 120 that extend from the interior surface 108. The ribs 120 are arranged in multiple rows 124 that are spaced from one another in a first direction (+X direction). For example, as shown in FIG. 2, the rows 124 of the ribs 120 can comprise a first row 124a of the ribs 120, a second row 124b of the ribs 120, a third row 124c of the ribs 120, a fourth row 124d of the ribs 120, a fifth row 124e of the ribs 120, and so on. In embodiments, the heat exchange apparatus 100 comprises at least 10 rows 124 of the ribs 120, such as 11, 12, 13, 14, 15, 20, 25, 30, 35, 40, or more rows 124 of the ribs 120. In embodiments, the rows 124 of the ribs 120 are parallel or substantially parallel to one another. In embodiments the rows 124 of the ribs 120 can be parallel over a portion of the interior surface 108 or over an entirety of the interior surface 108.

[0035] The ribs 120 are elongate in a second direction (+Y direction) that is orthogonal to the first direction (+X direction). For example, as best shown in FIG. 3, each rib 120 has an aspect ratio between a length I of the rib 120 in the second direction (+Y direction) and a width w of the rib in the first direction (+X direction). In embodiments, the aspect ratio of most of the ribs 120 is at least 15, such as 16, 17, 18, 19, 20, 25, 30, 35, or more. As used herein, “most” means greater than half of the number of ribs 120 of the heat exchange apparatus 100, such 51%, 60%, 70%, 80%, 90%, 95% or more of the ribs 120. In embodiments, an upper limit of the aspect ratio of the ribs 120 depends on various factors such as the material of the body 104 (e.g., if the body forms the ribs), the material of the ribs 120 (e.g., if the ribs are formed from a different material than the body and / or if the ribs are adhered or otherwise attached to the body), the mechanical strength of the material of the body and / or the material of the ribs, a height of the ribs 120 from the interior surface 108, and other factors discussed later in this disclosure (e.g., a flow rate and / or pressure of heat exchange fluid flowing through the cavity).

[0036] The ribs 120 within each row 124 are spaced from one another in the second direction (+Y direction) so as to define a gap G between adjacent ribs 120. In embodiments, the ribs 120 can comprise at least 5 ribs per row 124, such as 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 20, 25, or more ribs per row. In embodiments, the rows 124 can have the same number of ribs per row, or the rows 124 can have different numbers of ribs per row, for example, depending on a shape of a perimeter of the interior surface 108. In embodiments, one or more of the length I and the width w of the ribs 120 is the same (or substantially the same) for substantially all of the ribs 120 on the interior surface 120. In embodiments, the width w of the ribs 120 is the same (or substantially the same) for substantially all of the ribs 120 on the interior surface 108 while the length I of the ribs 120 is the same (or substantially the same) for most of theSP25-013ribs 120 on the interior surface 108. As used herein, “most” means greater than half of the number of ribs 120 of the heat exchange apparatus 100, such 51%, 60%, 70%, 80%, 90%, 95% or more of the ribs 120.

[0037] As best shown in FIGS. 3 and 4, the ribs 120 within each successive row (e.g., each second row 124b adjacent to and following a first row 124a) are offset along the second direction (Y direction) relative to the ribs 120 within a preceding row (e.g., a first row 124a adjacent to and preceding a second row 124b) such that most of the gaps G in the preceding row, when projected in the first direction (+X direction), intersect a respective rib 120 in the successive row. The projection of the gap G in the first direction (+X direction) is indicated by the dashed pairs of lines 128 extending between the first row 124a and the second row 124b in FIGS. 3 and 4. In embodiments, most of the gaps G in the preceding row completely intersect a respective rib 120 in the successive row when the gaps are projected in the first direction (+X direction). As used herein, “most” means greater than half of the number of gaps G of the heat exchange apparatus 100, such 51%, 60%, 70%, 80%, 90%, 95% or more of the gaps G.

[0038] In embodiments, as shown in FIGS. 3 and 4, the ribs 120 within each successive row 124b can have substantially the same offset along the second direction (Y direction) relative to the ribs within the preceding row 124a such that the rows 124 of the ribs 120 form a pattern (e.g., a repeating pattern of ribs 120 and gaps G) across the interior surface 108. In embodiments, as shown in FIG. 4, the ribs 120 are arranged such that a midpoint of the gap MG in the preceding row 124a intersects a midpoint of the respective rib MR in the successive row 124b when the gap G is projected in the first direction (+X direction) and when the midpoint of the gap MG and the midpoint of the respective rib MR are determined in the second direction (Y direction). The intersection of the midpoint of the gap MG and the midpoint of the respective rib MR is depicted in FIG. 4 by the dashed line 130 extending in the first direction (+X direction) through the midpoints MG, MR. In embodiments, such as those described in this paragraph, the ribs 120 can form a classical chessboard pattern in which the ribs 120 and the spaces between them are positioned in an alternating, chessboard-like pattern.

[0039] For example, the ribs 120 can be arranged such that they alternate with gaps or spaces in a regular, repeating sequence. This alternation can occur both within each row 124 and between adjacent rows (e.g., between a first row 124a and a second row 124b) as described above, similar to how the colors alternate on a chessboard. In embodiments, the ribs 120 within each row 124 are spaced apart at regular intervals, forming a pattern of ribs 120 and gaps G. The rows 124 of ribs 120 are offset from each other (e.g., along the second direction), such thatSP25-013the gaps G in one row (e.g., the first row 124a) align with the ribs 120 in the adjacent row (e.g., the second row 124b). The overall arrangement of the ribs 120 and gaps G forms a visually and geometrically regular structure that mimics the alternating squares of a chessboard.

[0040] Referring now to FIGS. 5A and 5B, detail views of the same portion of the heat exchange apparatus 100 (e.g., indicated by the dashed region 5 in FIG. 4) are shown. The ribs 120 are configured to define a plurality of mixing units 132. As shown in FIGS. 5A and 5B, each mixing unit 132 comprises, in a preceding row (e.g., a first row 124a), a first rib 120a, a second rib 120b adjacent to the first rib 120a in the second direction (+Y direction), and a first gap G1 between the first rib 120a and the second rib 120b. Each mixing unit 132 further comprises, in a successive row (e.g., a second row 124b) spaced from the preceding row 124a in the first direction (+X direction), a third rib 120c, a fourth rib 120d adjacent to the third rib 120c in the second direction (+Y direction), a second gap G2 between the third rib 120c and the fourth rib 120d, a fifth rib 120e adjacent to the fourth rib 120d in the second direction (+Y direction), and a third gap G3 between the fourth rib 120d and the fifth rib 120e. While FIGS.5A and 5B show an example of one mixing unit 132 corresponding to the dashed region 5 in FIG. 4, the dashed region 5 can encompass any group of ribs 120 that comprises a first rib 120a, a second rib 120b, a third rib 120c, a fourth rib 120d, and a fifth rib 120e arranged in the manner described with reference to FIGS. 5 A and 5B.

[0041] Referring now to FIG. 5 A, the first gap G1 defines a first distance dl in the second direction (Y direction). The first rib 120a has an edge 136a that defines one side of the first gap G1 and the second rib 120b has an edge 136b that defines the other side of the first gap Gl. The fourth rib 120d has a first edge 136d 1 that defines one side of the second gap G2 and a second edge 136d2 that defines one side of the third gap G3. A distance in the second direction (Y direction) between the edge 136a of the first rib 120a and a projection ofthe first edge 136dl of the fourth rib 120d (e.g., closest to the edge 136a ofthe first rib 120a) onto the first rib 120a in a direction opposite the first direction (-X direction) defines a second distance d2. A distance in the second direction between the edge 136b of the second rib 120b and a projection of the second edge 136d2 ofthe fourth rib 120d (e.g., closest to the edge 136b ofthe second rib 120b) onto the second rib 120b in a direction opposite the first direction (-X direction) also defines the second distance d2. The projections of the first edge 136dl and the second edge 136d2 of the fourth rib 120b onto the first rib 120a and the second rib 120b, respectively, are schematically depicted by dashed lines 138.SP25-013

[0042] Referring still to FIG. 5A, a distance in the first direction (+X direction) between the first rib 120a and the fourth rib 120d defines a third distance d3. A distance in the first direction (+X direction) between the second rib 120b and the fourth rib 120d also defines the third distance d3. In embodiments, the second distance d2 is greater than the first distance dl, and the first distance dl and the third distance d3 are approximately equal. As discussed later in this disclosure, the relationships among the first distance dl, the second distance d2, and the third distance d3 provide the mixing unit 132 with a pressure gradient that enables heat exchange fluid flowing through the heat exchange apparatus 100 to have both lateral flow (e.g., schematically indicated by the bolded, horizontal arrows in FIG. 4) and crosswise flow (e.g., indicated by the bolded, vertical arrows in FIG. 4).

[0043] In embodiments, as shown in FIGS. 1-3, the ribs 120 extend from the interior surface 108 of the body 104 in a third direction (+Z direction) that is orthogonal to the first direction (+X direction) and the second direction (+Y direction). The first side 116 of the body 104 has a first surface 148 that is planar (e.g., substantially planar) and offset from the interior surface 108 in the third direction (+X direction). In embodiments, a seal (not shown) is disposed between the first surface 148 and a separate component (e.g., the process fluid module 10 discussed later in this disclosure) and / or an external surface (e.g., an external major surface) of the separate component. In such embodiments, the seal (e.g., an O-ring, a sealing material, or the like) surrounds the interior surface 108 so that the seal and the separate component and / or the external surface of the separate component close the cavity 112 in the body 104 of the heat exchange apparatus 100 when the seal is compressed between the body 104 and the separate component.

[0044] In embodiments, as shown in FIGS. 1-3, the heat exchange apparatus 100 comprises a groove 152 in the first surface 148. The groove 152 surrounds the interior surface 108 and has a lateral offset (e.g., a lateral offset parallel to the XY plane) from the interior surface 108 such that a portion of the first surface 148 is disposed on each side of the groove 152. The groove 152 is configured to receive the seal. In embodiments, the seal can protrude higher than the first surface 148 so that the seal and the separate component can seal the cavity 112 without contact between the heat exchange apparatus 100 and the separate component.

[0045] In embodiments, as shown in FIGS. 1-3, the interior surface 108 comprises a major surface portion 156 that is planar and oriented normal to the third direction (+Z direction). In such embodiments, the ribs 120 can extend from the major surface portion 156 of the interior surface 108. In embodiments, the ribs 120 extend from the major surface portion 156 in theSP25-013third direction (+Z direction). In embodiments, the interior surface 108 comprises a minor surface portion 160 that surrounds the major surface portion 156 and extends in the third direction (+Z direction) from the major surface portion 156. In embodiments, the minor surface portion 160 of the interior surface 108 extends from the major surface portion 156 to the first surface 148.

[0046] As best shown in FIG. 3, the ribs 120 have a height h from the interior surface 108 of the body 104 in the third direction (+Z direction), and the first surface 148 has an offset 164 from the interior surface 108 of the body 104 in the third direction (+Z direction). In embodiments, the height h of the ribs 120 from the interior surface 108 in the third direction (+Z direction) is less than the offset 164 of the first surface 164 from the interior surface 108 in the third direction (+Z direction). In embodiments, the height h of the ribs 120 from the major surface portion 156 of the interior surface 108 in the third direction (+Z direction) is less than the offset 164 of the first surface 148 from the major surface portion 156 of the interior surface 108 in the third direction (+Z direction). As discussed later in the disclosure, the lower height h of the ribs 120 relative to the offset 164 of the first surface 148 is configured to form a clearance C (FIG. 7) that enables the crosswise flow (e.g., indicated by the bolded, vertical arrows in FIG. 4) when the cavity 112 of the heat exchange apparatus 100 is sealed against an external surface and heat exchange fluid is flowed through the cavity 112.

[0047] Referring again to FIGS. 1-4, the heat exchange apparatus 100 further comprises at least two ports 168, 170 opening to the cavity 112 through the interior surface 108 of the body 104. In embodiments, the ports 168, 170 are utilized to flow heat exchange fluid through the cavity 112 of the heat exchange apparatus 100. In such embodiments, one of the ports is an inflow port 168 configured to deliver the heat exchange fluid to the cavity 112 of the heat exchange apparatus 100 and the other of the ports is an outflow port 170 configured to receive the heat exchange fluid from the cavity 112 of the heat exchange apparatus 100. In embodiments, the heat exchange apparatus 100 can have one or more inflow ports 168 and one or more outflow ports 170. For example, in the exemplary embodiment shown in FIGS. 1 and 2, the heat exchange apparatus 100 comprises two inflow ports 168 spaced from one another in the second direction (+Y direction) and two outflow ports 170 spaced from one another in the second direction (+Y direction).

[0048] As shown in FIGS. 1 and 2, the inflow port(s) 168 and the outflow port(s) 170 are spaced from one another along the first direction (X direction). In embodiments, the ports 168, 170 are spaced such that one of the ports (e.g., the inflow port(s) 168) is positioned near theSP25-013perimeter of the interior surface 108 on a first side and the other of the ports (e.g., the outflow port(s) 170) is positioned near the perimeter of the interior surface 108 on a second side opposite the first side in the first direction (+X direction). In such embodiments, the inflow port(s) 168 and the outflow port(s) 170 are positioned to maximize the spacing therebetween in the first direction (+X direction) so as to maximize the number of ribs 120 and the number of gaps G between the ports 168, 170. In the exemplary embodiment shown in FIGS. 1 and 2, the two inflow ports 168 are spaced from the two outflow ports 170 in first direction (+X direction).

[0049] Referring now to FIG. 6, a flow reactor module 200 is shown according to embodiments of the present disclosure. The flow reactor module 200 comprises a process fluid module, such as the process fluid module 10 described in connection with FIG. 13, and a first heat exchange apparatus, such as the heat exchange apparatus 100 described herein with reference to FIGS. 1-5. In the following description of the flow reactor module 200, like reference numerals will be used to indicate elements of the process fluid module 10 and the heat exchange apparatus 100 previously described and new reference numerous will be used to indicate new or modified elements of these components. FIG. 6 shows the process fluid module 10 sectioned along a section plane (e.g., generally parallel to the XZ plane) for reference only to better illustrate features of the heat exchange apparatus 100 and the positional relationship of those features to the process fluid module 10.

[0050] As shown in FIGS. 6 and 13, the process fluid module 10 comprises an extended body having a width W, a length L, and a thickness T that is less than the length L and less than the width W. The process fluid module 10 has a process fluid passage P extending therethrough. FIG. 15 shows a perspective view of the process fluid module 10 with detail of an embodiment of the process fluid passage P, such as may be used in the context of the present disclosure. The process fluid module 10 has a first major surface 12 and a second major surface 14 disposed on opposite sides of the process fluid module 10. In embodiments, the first major surface 12 and the second major surface 14 are oriented perpendicularly to a direction of the thickness T of the process fluid module 10 (e.g., the third direction orZ direction illustrated in FIG. 6).

[0051] As shown in FIG. 6, the heat exchange apparatus 100 is sealed against the first major surface 12 of the process fluid module 10. The heat exchange apparatus 100 of FIGS. 6 and 7 comprises the body 104, the interior surface 108, the cavity 112, and the first side 116 as described above with reference to FIGS. 1-5. In embodiments, such as shown in FIG. 6, theSP25-013plate-like shape of the body 104 of the heat exchange apparatus 100 is oriented so as to substantially align to the extended body (e.g., plate-like shape) of the process fluid module 10. When the first side 116 (e.g., first surface 148) of the heat exchange apparatus 100 is sealed with the first major surface 12 of the process fluid module 10, the cavity 112 of the heat exchange apparatus 100 is closed by the first major surface 12 and the heat exchange fluid is contained against the first major surface of the process fluid module 10.

[0052] In embodiments, the flow reactor module 200 comprises the seal (not shown) as described above with reference to FIGS. 1-3. The seal is positioned between the first surface 148 of the heat exchange apparatus 100 and the first major surface 12 of the process fluid module 10 to seal the heat exchange apparatus 100 to the process fluid module 10. In embodiments, the seal is positioned within the groove 152 as described above with reference to FIGS. 1-3. In embodiments, the groove 152 can be disposed in the first surface 148 of the heat exchange apparatus 100, as previously described, or in the first major surface 12 of the process fluid module 10 or in portions of both the first surface 148 and the first major surface 12.

[0053] In embodiments, there is no direct contact between the process fluid module 10 and the heat exchange apparatus 100. Instead, for example, the contact is between the heat exchange apparatus 100 and a plurality of spacers (not shown) that can be disposed about the periphery of the process fluid module 10. In such embodiments, the thickness T of the process fluid module 10 is slightly less than the height of the spacers so that the seal (e.g., O-ring) is slightly compressed between the first surface 148 of the heat exchange apparatus 100 and the first major surface 12 of the process fluid module 10 to seal the cavity 112 of the heat exchange apparatus 100. FIG. 6 shows an exaggeration of the no contact condition between the process fluid module 10 and the heat exchange apparatus 100. In such embodiments, the seal is configured to occupy any clearance between the process fluid module 10 and the heat exchange apparatus 100 to contain the heat exchange fluid against the first major surface 12 of the process fluid module 10.

[0054] The heat exchange apparatus 100 of FIG. 6 further comprises the ribs 120, the gaps G, and all corresponding features thereof as described above with reference to FIGS. 1-5. The ribs 120 are configured to define a heat exchange fluid path HP for the heat exchange fluid. The heat exchange apparatus 100 of FIG. 6 further comprises an inflow port 168 an outflow port 170. The inflow port 168 extends through the body 104 and opens to the cavity 112 through the interior surface 108. The inflow port 168 is configured to deliver the heat exchange fluid toSP25-013the heat exchange fluid path HP of the heat exchange apparatus 100. The outflow port 170 extends through the body 104 and opens to the cavity 112 through the interior surface 108. The outflow port 170 is configured to receive the heat exchange fluid from the heat exchange fluid path HP of the heat exchange apparatus. The outflow port 170 is spaced from the inflow port 168 in the first direction (+X direction), as shown in FIG. 6.

[0055] Referring now to FIG. 7, further aspects of the ribs 120 are shown. FIG. 7 is a schematic cross section through a portion of the flow reactor module 200 along the section plane (e.g., along which the process fluid module 10 is sectioned in FIG. 6). In embodiments, the first major surface 12 and the second major surface 14 of the process fluid module 10 are oriented perpendicularly to the third direction (Z direction). In such embodiments, the height h of the ribs 120 is configured such that there is a clearance C between the ribs 120 of the heat exchange apparatus 100 and the first major surface 12 of the process fluid module 10. As previously discussed with reference to FIG. 3, the clearance C enables the crosswise flow (e.g., indicated by the bolded, vertical arrows in FIG. 4) when the cavity 112 of the heat exchange apparatus 100 is closed by the seal and the first major surface 12 and the heat exchange fluid is flowed through the heat exchange fluid path HP formed by the cavity 112 and the ribs 120. The crosswise flow is further illustrated in FIG. 7 by the four arrows F converging above the rib 120 to pass through the flow constriction formed by the clearance C. This flow constriction is configured to locally increase the Nusselt number and better agitate the heat exchange fluid.

[0056] The ribs 120 of the heat exchange apparatus 100 of FIGS. 6 and 7 define the mixing units 132 as described above with reference to FIGS. 4, 5A, and 5B. As previously described, each mixing unit 132 comprises, in a preceding row 124a, a first rib 120a, a second rib 120b, a first gap G1 (e.g., between the first rib 120a and the second rib 120b) and, in a successive row 124b, a third rib 120c, a fourth rib 120d, a fifth rib 120e, a second gap G2 (e.g., between the third rib 120c and the fourth rib 120d), and a third gap G3 (e.g., between the fourth rib 120d and the fifth rib 120e.

[0057] Referring again to FIG. 5B, further features of the mixing units 132 are shown. As shown in FIG. 5B, a first portion of the heat exchange fluid is configured to flow through the first gap G1 in the first direction (+X direction) towards a first side 174dl of the fourth rib 120d. The first portion of the heat exchange fluid has a first pressure Pl measured proximate the first side 174d 1 and within the projection 128 of the first gap G1 in the first direction (+X direction). A second portion of the heat exchange fluid is configured to impinge upon the first side 174dl of the fourth rib 120d and flow laterally (e.g., lateral flow schematically indicatedSP25-013by the bolded, horizontal arrows in FIG. 4) towards the second gap G2 between the third rib 120c and the fourth rib 120d or the third gap G3 between the fourth rib 120d and the fifth rib 120e. The second portion of the heat exchange fluid has a second pressure P2 measured proximate the second gap G2 or the third gap G3.

[0058] Referring still to FIG. 5B, a third portion of the heat exchange fluid is configured to flow in the first direction (+X direction) and flow crosswise (e.g., crosswise flow schematically indicated by the bolded, vertical arrows in FIG. 4) through the clearance C (FIG. 7) between the fourth rib 120d and the first major surface 12. The third portion of the heat exchange fluid has a third pressure P3 measured proximate a second side 174d2 of the fourth rib 120d that is opposite the first side 174dl of the fourth rib 120d. In embodiments, a relationship among the first pressure Pl, the second pressure P2, and the third pressure P3 follows the equation: Pl - P2 > Pl - P3.

[0059] In embodiments, the flow reactor module 200 further comprises a second heat exchange apparatus (now shown) sealed against the second major surface 14 of the process fluid module 10. The second heat exchange apparatus can be configured in the same manner as the heat exchange apparatus 100 described above with respect to FIGS. 1-7.

[0060] Referring now to FIG. 8, a heat exchange apparatus 300 is shown in an alternative configuration in which the ribs are provided on opposite sides of the body. The heat exchange apparatus 300 of FIG. 8 is similar to the heat exchange apparatus 100 previously described with reference to FIGS. 1-7. In the following description, like reference numerals are used to indicate like elements of the heat exchange apparatuses 100, 300 and new reference numerals are used to indicate new or modified elements of the heat exchange apparatus 300. The letters “a” and “b” may be appended to the reference numerals to indicate like elements that are disposed at different locations or different sides of the heat exchange apparatus 300.

[0061] FIG. 8 is a series of orthogonal plan views of the heat exchange apparatus 300 showing a first or top side 116 of the body 104 (left view in FIG. 8), a second or bottom side 118 of the body 104 that is opposite the first side 116 (right view in FIG. 8), and an edge 190 that extends between the first side 116 and the second side 118 (center view in FIG. 8). As shown in FIG. 8, on the first side 116 of the body 104, the heat exchange apparatus 300 comprises a first interior surface 108a, a first cavity (not shown), and a first plurality of ribs 120a (hereinafter “first ribs”) corresponding to the interior surface 108, the cavity 112, and theSP25-013plurality of ribs 120, respectively, of the heat exchange apparatus 100 described above with reference to FIGS. 1-5.

[0062] The heat exchange apparatus 300 further comprises a second interior surface 108b, a second cavity (not shown), and a second plurality of ribs 120b (hereinafter “second ribs”) on the second side 118 of the body 104. In embodiments, such as shown in FIG. 8, the second interior surface 108b, the second cavity, and the second ribs 120b are symmetrical (e.g., mirror symmetrical) to the first interior surface 108a, the first cavity, and the first ribs 120a, respectively, about a symmetry plane 194. In embodiments, the first ribs 120a and the second ribs 120b are not mirror symmetrical and can differ with respect to any attribute (e.g., height h, length I, width w, aspect ratio, number per row, number of rows, etc.) described above with respect to the ribs 120 of the heat exchange apparatus 100.

[0063] The heat exchange apparatus 300 of FIG. 8 further comprises the one or more inflow ports 168 and the one or more outflow ports 170 as described above with reference to the heat exchange apparatus 100 of FIGS. 1-5. As shown in FIG. 8, each of the ports 168, 170 is configured to open to the first cavity and the second cavity through the first interior surface 108a and the second interior surface 108b, respectively. In embodiments, as shown in FIG. 8, the heat exchange fluid can be communicated to and from the inflow ports 168 and the outflow ports 170 through fluid channels 198 extending through the body 104 and opening to the edge 190.

[0064] In embodiments, the flow reactor module 200 further comprises a second process fluid module (not shown) that is configured in substantially the same manner as the process fluid module 10 described above with reference to FIGS. 6 and 13 (hereinafter “first process fluid module”). The first major surface 12 and the second major surface 14 of the second process fluid module are oriented perpendicularly to the direction of the thickness T of the second process fluid module 10 (e.g., the third direction or Z direction illustrated in FIG. 6). The first process fluid and the second process fluid module are spatially oriented in substantially the same manner and spaced from one another in the third direction.EXAMPLES

[0065] The various embodiments of the present disclosure can be better understood by reference to the following Examples which are offered by way of illustration. The present disclosure is not limited to the Examples given herein.Example 1 Simulation ParametersSP25-013

[0066] A simulation was performed to assess flow velocity magnitude of heat exchange fluid flowed through a single heat exchange apparatus that comprises the various features described herein. The heat exchange apparatus model used in the simulation corresponds to the heat exchange apparatus 100 shown in FIGS. 1-5 with the following feature dimensions. An external surface that corresponds to the first major surface 12 of the process fluid module 10 shown in FIGS. 6 and 7 was used to close the cavity 112 of the heat exchange apparatus module.

[0067] For each full rib 120 (e.g., a rib not shortened in length I due to its proximity with the ports 168, 170 and / or the perimeter of the interior surface 108), the rib 120 has a length I of about 18 mm, a width w of about 1 mm, and a height h of about 1.25 mm. The aspect ratio of each full rib 120 is about 18. For any partial rib 120 (e.g., a rib shortened in length I due to its proximity with the ports 168, 170 and / or the perimeter of the interior surface 108), the rib 120 has a width w of about 1 mm and a height h of about 1.25 mm. The length I of the partial ribs is variable in order to maintain the pattern of ribs 120 and gaps G across the interior surface 108 as described throughout the disclosure.

[0068] The first surface 148 has an offset from the interior surface 108 in the third direction (+Z direction) of about 1.5 mm. The clearance C between the top of the ribs 120 and the external surface that closes the cavity 112 (e.g., the first major surface 12 of the process fluid module 10 shown in FIG. 6) is about 0.25 mm.

[0069] The gaps G between all adjacent ribs 120 (e.g., full ribs and partial ribs) in the second direction (+Y direction) is about 6 mm such that the first distance dl (FIG. 5 A) is about 6 mm. The heat exchange apparatus model used in the simulation has 39 parallel rows of ribs 120. The spacing between each row 124 of the ribs 120 in the first direction (+X direction) is about 6 mm such that the third distance d3 (FIG. 5A) is about 6 mm. The second distance d2 (FIG. 5A) is about 6 mm on each side of the first gap G1.

[0070] The heat exchange apparatus used in the simulation has a first inflow port 168 (e.g., leftmost port 168 in FIG. 2) and a second inflow port 168 (e.g., rightmost port 168 in FIG. 2) spaced from the first inflow port 168 in the second direction (+Y direction). The heat exchange apparatus used in the simulation also has a first outflow port 170 (e.g., leftmost port 170 in FIG. 2) and a second inflow port 170 (e.g., right most port 170 in FIG. 2) spaced from the first outflow port 170 in the second direction (+Y direction). The outflow ports 170 are spaced from the inflow ports 168 in the first direction (+X direction). The inflow ports 168 and the outflow ports 170 have an oval-like shape with dimensions along a major axis in a range of about 68SP25-013mm to about 73 mm and dimensions along a minor axis in a range of about 28 mm to about 30 mm.

[0071] The heat exchange fluid used in the simulation was water. In the simulation, the water was flowed into the heat exchange apparatus at a flow rate of 40 L / min with the flow equally distributed through both inflow ports 168.Example 2 Simulation Output: Flow Velocity Magnitude Through Clearances and Gaps

[0072] FIG. 9 depicts the velocity magnitude of the flowing water in a vertical cross section (e.g., parallel to the XZ plane) passing through the clearance C (FIG. 7) between a single rib 120 and the modeled external surface (e.g., the first major surface 12). The flow direction in FIG. 9 is from left to right in the direction of the arrow F. As shown in FIG. 9, the maximum velocity magnitude of the water occurs at a top, leading edge of the rib 120 and continues through the entire constriction over the rib 120.

[0073] FIG. 10 depicts the velocity magnitude of the flowing water in a first horizontal cross section (e.g., parallel to the XY plane and indicated by reference numeral 178 in FIG. 9) passing through the clearance C. As a result of the dimensional and pressure relationships depicted in FIGS. 5A and 5B, a first region 182 of high velocity magnitude flow will occur over each rib on which the gap G between proceeding adjacent ribs is projected since the gap G will direct the heat exchange fluid to impinge directly upon (and over) each such rib, such as depicted in FIG. 9. Due to the repeating pattern of the ribs 120 and the gaps G arranged on the interior surface 108 of the heat exchange apparatus 100, the first region 182 of high velocity magnitude flow will have a similar repeating pattern across the interior surface 108.

[0074] FIG. 11 depicts the velocity magnitude of the flowing water in a second horizontal cross section (e.g., parallel to the XY plane and indicated by reference numeral 182 in FIG. 9) positioned closer to the interior surface 108 and passing through the rib 120. As a result of the dimensional and pressure relationships depicted in FIGS. 5 A and 5B, a second region 184 of high velocity magnitude flow will occur within each gap G. Over at least some portions of the interior surface 108, the second region 184 may concentrate within the gap G proximate the edges of the adjacent ribs 120 that form the gap G. Due to the repeating pattern of the ribs 120 and the gaps G arranged on the interior surface 108 of the heat exchange apparatus 100, the second region 184 of high velocity magnitude flow will have a similar repeating pattern across the interior surface 108.SP25-013

[0075] Referring now to FIG. 12, a portion of the velocity magnitude of the flowing water depicted in FIG. 11 (e.g., indicated by region 11 in FIG. 11) is shown to illustrate further aspects of the second region 184 of high velocity magnitude flow. As shown in FIG. 12, over at least some portions of the interior surface 108, the second regions 184 of high velocity magnitude flow are linked together by secondary flows 186 of the water having similarly high velocity magnitude as the secondary regions 184. These secondary flows 186 of the water repeatedly diverge and converge as the water flows through the heat exchange apparatus 100. For example, as shown in FIG. 12, a first secondary flow 186a and a second secondary flow 186b diverge as they impinge upon the rib on which the gap G between proceeding adjacent ribs is projected. After this divergence, the first secondary flow 186a and the second secondary flow 186 flow around the impinged upon rib and converge towards one another as they flow towards the next gap G. The pattern of first regions 180, second regions 184, and secondary flows 186 are configured to locally increase Nusselt number and, therefore, better agitate the heat exchange fluid.

[0076] The subject-matter of the disclosure may also relate, among others, to the following aspects:

[0077] According to aspect (1), a heat exchange apparatus is provided. The heat exchange apparatus comprises: a body having an interior surface configured to define a cavity that opens to a first side of the body; a plurality of ribs extending from the interior surface, the ribs arranged in multiple rows that are spaced from one another in a first direction; and at least two ports opening to the cavity through the interior surface, the at least two ports spaced from one another in the first direction, wherein the ribs are elongate in a second direction that is orthogonal to the first direction, the ribs within each row being spaced from one another in the second direction so as to define a gap between adjacent ribs, and wherein the ribs within each successive row are offset along the second direction relative to the ribs within a preceding row such that most of the gaps in the preceding row, when projected in the first direction, intersect a respective rib in the successive row.

[0078] According to aspect (2), the heat exchange apparatus of aspect (1) is provided, wherein each rib has an aspect ratio between a length of the rib in the second direction and a width of the rib in the first direction, and wherein the aspect ratio of most of the ribs is at least 15.SP25-013

[0079] According to aspect (3), the heat exchange apparatus of aspect (1) or aspect (2) is provided, wherein the ribs within each successive row have substantially the same offset along the second direction relative to the ribs within the preceding row.

[0080] According to aspect (4), the heat exchange apparatus of any one of aspects (1) to (3) is provided, wherein a midpoint of the gap in the preceding row intersects a midpoint of the respective rib in the successive row when the gap is projected in the first direction and when the midpoint of the gap and the midpoint of the respective rib are determined in the second direction.

[0081] According to aspect (5), the heat exchange apparatus of any one of aspects (1) to (4) is provided, wherein: (i) the ribs define a plurality of mixing units, each mixing unit comprising: (a) in a preceding row, a first rib, a second rib adjacent to the first rib in the second direction, and a first gap between the first rib and the second rib, and (b) in a successive row spaced from the preceding row in the first direction, a third rib, a fourth rib adjacent to the third rib in the second direction, a second gap between the third rib and the fourth rib, a fifth rib adjacent to the fourth rib in the second direction, and a third gap between the fourth rib and the fifth rib, and (ii) within each mixing unit: (a) the first gap defines a first distance in the second direction, (b) a distance in the second direction between an edge of the first rib and a projection of an edge of the fourth rib onto the first rib in a direction opposite the first direction defines a second distance, (c) a distance in the first direction between the first rib and the fourth rib defines a third distance, (d) the second distance is greater than the first distance, and (e) the first distance and the third distance are approximately equal.

[0082] According to aspect (6), the heat exchange apparatus of any one of aspects (1) to (5) is provided, wherein the ribs extend from the interior surface in a third direction that is orthogonal to the first direction and the second direction.

[0083] According to aspect (7), the heat exchange apparatus of aspect (6) is provided, wherein the first side of the body comprises a first surface that is planar and offset from the interior surface in the third direction, the cavity opening to the first surface.

[0084] According to aspect (8), the heat exchange apparatus of aspect (7) is provided, wherein the interior surface comprises a major surface portion that is planar and oriented normal to the third direction, the ribs extending from the major surface portion.SP25-013

[0085] According to aspect (9), the heat exchange apparatus of aspect (8) is provided, wherein the interior surface comprises a minor surface portion that surrounds the major surface portion and extends in the third direction from the major surface portion to the first surface.

[0086] According to aspect (10), the heat exchange apparatus of any one of aspects (7) to (9) is provided, wherein a height of the ribs from the interior surface in the third direction is less than the offset of the first surface from the interior surface in the third direction.

[0087] According to aspect (11), the heat exchange apparatus of aspect (8) or aspect (9) is provided, wherein a height of the ribs from the major surface portion in the third direction is less than the offset of the first surface from the major surface portion in the third direction.

[0088] According to aspect (12), the heat exchange apparatus of any one of aspects (7) to (11) is provided, further comprising a groove in the first surface, the groove surrounding the interior surface with a portion of the first surface on each side of the groove.

[0089] According to aspect (13), the heat exchange apparatus of any one of aspects (1) to (12) is provided, wherein the body has a plate-like shape comprising a length, a width, and a thickness that is less than the length and less than the width.

[0090] According to aspect (14), the heat exchange apparatus of any one of aspects (1) to (13) is provided, wherein the rows of the ribs are parallel to one another.

[0091] According to aspect (15), the heat exchange apparatus of any one of aspects (1) to (14) is provided, wherein one or more of (i) the rows of the ribs comprise at least 10 rows of the ribs and (ii) the ribs within each row comprise at least 5 ribs per row.

[0092] According to aspect (16), a flow reactor module is provided. The flow reactor module comprises: a first process fluid module with a process fluid passage extending therethrough, the first process fluid module comprising an extended body having a width, a length, and a thickness that is less than the width and less than the length, the first process fluid module having a first major surface and a second major surface disposed on opposite sides of the first process fluid module; a first heat exchange apparatus sealed against the first major surface of the first process fluid module, the first heat exchange apparatus comprising: a body having a first side with an interior surface that defines a cavity configured to contain heat exchange fluid against the first major surface of the first process fluid module, a plurality of ribs extending from the interior surface to define a heat exchange fluid path for the heat exchange fluid, the ribs arranged in multiple rows that are spaced from one another in a first direction, at least one inflow port extending through the body and opening to the cavity throughSP25-013the interior surface, the at least one inflow port configured to deliver the heat exchange fluid to the heat exchange fluid path, and at least one outflow port extending through the body and opening to the cavity through the interior surface, the at least one outflow port configured to receive the heat exchange fluid from the heat exchange fluid path, the at least one outflow port spaced from the at least one inflow port in the first direction, wherein the ribs are elongate in a second direction that is orthogonal to the first direction, the ribs within each row being spaced from one another in the second direction so as to define a gap between adjacent ribs, and wherein the ribs within each successive row are offset along the second direction relative to the ribs within a preceding row such that most of the gaps in the preceding row, when projected in the first direction, intersect a respective rib in the successive row.

[0093] According to aspect (17), the flow reactor module of aspect (16) is provided, wherein each rib of the first heat exchange apparatus has an aspect ratio between a length of the rib in the second direction and a width of the rib in the first direction, and wherein the aspect ratio of most of the ribs is at least 15.

[0094] According to aspect (18), the flow reactor module of aspect (16) or aspect (17) is provided, wherein the first and second major surfaces of the first process fluid module are oriented perpendicularly to a third direction that is orthogonal to the first direction and the second direction and corresponds the thickness of the first process fluid module, and wherein there is a clearance between the ribs of the first heat exchange apparatus and the first major surface of the first process fluid module.

[0095] According to aspect (19), the flow reactor module of aspect (18) is provided, wherein: (i) the ribs of the first heat exchange apparatus define a plurality of mixing units, each mixing unit comprising: (a) in a preceding row, a first rib, a second rib adjacent to the first rib in the second direction, and a first gap between the first rib and the second rib, and (b) in a successive row spaced from the preceding row in the first direction, a third rib, a fourth rib adjacent to the third rib in the second direction, a second gap between the third rib and the fourth rib, a fifth rib adjacent to the fourth rib in the second direction, and a third gap between the fourth rib and the fifth rib, (ii) within each mixing unit: (a) the first gap defines a first distance (dl) in the second direction, (b) a length in the second direction between an edge of the first rib and a projection of an edge of the fourth rib (closest to the edge of the first rib) onto the first rib in a direction opposite the first direction defines a second distance (d2), (c) a spacing in the first direction between the first rib and the third rib defines a third distance (d3), (d) theSP25-013second distance (d2) is greater than the first distance (dl), and (e) the first distance (dl) and the third distance (d3) are approximately equal.

[0096] According to aspect (20), the flow reactor module of aspect (19) is provided, wherein, within each mixing unit: a first portion of the heat exchange fluid is configured to flow through the first gap in the first direction towards a first side of the fourth rib, the first portion having a first pressure measured proximate the first side, a second portion of the heat exchange fluid is configured to impinge upon the first side of the fourth rib and flow laterally towards the second gap between the third rib and the fourth rib or the third gap between the fourth rib and the fifth rib, the second portion having a second pressure measured proximate the second gap or the third gap, a third portion of the heat exchange fluid is configured to flow in the first direction through the clearance between the fourth rib and the first major surface, the third portion having a third pressure measured proximate a second side of the fourth rib that is opposite the first side, and a relationship among the first pressure, the second pressure, and the third pressure follows the equation: P1 - P2 > P1 - P3.

[0097] According to aspect (21), the flow reactor module of any one of aspects (18) to (20) is provided, wherein the ribs of the first heat exchange apparatus extend from the interior surface in the third direction.

[0098] According to aspect (22), the flow reactor module of any one of aspects ( 18) to (21 ) is provided, wherein the body of the first heat exchange apparatus comprises a first surface that is planar and offset from the interior surface in the third direction, the first surface configured to receive a seal that surrounds the interior surface and abuts the first major surface of the first process fluid module.

[0099] According to aspect (23), the flow reactor module of any one of aspects ( 18) to (22) is provided, wherein the interior surface of the first heat exchange apparatus comprises a major surface portion that is planar and oriented normal to the third direction, the ribs extending from the major surface portion.

[0100] According to aspect (24), the flow reactor module of any one of aspects (16) to (23) is provided, wherein the rows of the ribs of the first heat exchange apparatus are parallel to one another.

[0101] According to aspect (25), the flow reactor module of any one of aspects (16) to (24) is provided, wherein one or more of (i) the rows of the ribs of the first heat exchange apparatusSP25-013comprise at least 10 rows of the ribs and (ii) the ribs within each row comprise at least 5 ribs per row.

[0102] According to aspect (26), the flow reactor module of any one of aspects (16) to (25) is provided, further comprising a second heat exchange apparatus sealed against the second major surface of the first process fluid module, the second heat exchange apparatus configured in substantially the same manner as the first heat exchange apparatus.

[0103] According to aspect (27), the flow reactor module of any one of aspects (16) to (25) is provided, further comprising a second process fluid module configured in substantially the same manner as the first process fluid module, the second process fluid module spaced from the first process fluid module in a third direction that is orthogonal to the first direction and the second direction, wherein: the second major surface of the second process fluid module faces the first major surface of the first process fluid module, the body of the first heat exchange apparatus has a second side opposite the first side, the second side having a second interior surface, a second cavity, and a second plurality of ribs that are symmetrical about a symmetry plane to the interior surface, the cavity, and the plurality of ribs, respectively, on the first side of the body, wherein the at least one inflow port and the at least one outflow port extend in the third direction and open to the second cavity through the second interior surface, and the second side of the heat exchange apparatus is sealed against the second major surface of the second process fluid module to contain the heat exchange fluid against the second major surface.

[0104] While the disclosure has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications, and further applications that come within the spirit of the disclosure are desired to be protected. For example, while specific dimensions have been disclosed in the Example in connection with the heat exchange apparatus model used in the simulation, the heat exchange apparatus described throughout this disclosure should not be limited to such specific dimensions. For completeness, it is intended that any dimension or value disclosed herein be considered to constitute the specific dimension or value, in one embodiment, and the dimension or value modified by a + / - tolerance of 1%, 2%, 3%, 4%, 5%, 10%, 15%, or 20%, in another embodiment.

Claims

SP25-013CLAIMSWhat is claimed is:

1. A heat exchange apparatus, comprising:a body having an interior surface configured to define a cavity that opens to a first side of the body;a plurality of ribs extending from the interior surface, the ribs arranged in multiple rows that are spaced from one another in a first direction; andat least two ports opening to the cavity through the interior surface, the at least two ports spaced from one another in the first direction,wherein the ribs are elongate in a second direction that is orthogonal to the first direction, the ribs within each row being spaced from one another in the second direction so as to define a gap between adjacent ribs, andwherein the ribs within each successive row are offset along the second direction relative to the ribs within a preceding row such that most of the gaps in the preceding row, when projected in the first direction, intersect a respective rib in the successive row.

2. The heat exchange apparatus of claim 1, wherein each rib of the ribs has an aspect ratio between a length of the rib in the second direction and a width of the rib in the first direction, and wherein the aspect ratio of most of the ribs is at least 15.

3. The heat exchange apparatus of claim 1 or claim 2, wherein the ribs within each successive row have substantially the same offset along the second direction relative to the ribs within the preceding row.

4. The heat exchange apparatus of any one of claims 1-3, wherein a midpoint of the gap in the preceding row intersects a midpoint of the respective rib in the successive row when the gap is projected in the first direction and when the midpoint of the gap and the midpoint of the respective rib are determined in the second direction.SP25-0135. The heat exchange apparatus of any one of claims 1-4, wherein:(i) the ribs define a plurality of mixing units, each mixing unit comprising:(a) in the preceding row, a first rib, a second rib adjacent to the first rib in the second direction, and a first gap between the first rib and the second rib, and(b) in a successive row spaced from the preceding row in the first direction, a third rib, a fourth rib adjacent to the third rib in the second direction, a second gap between the third rib and the fourth rib, a fifth rib adjacent to the fourth rib in the second direction, and a third gap between the fourth rib and the fifth rib, and(ii) within each mixing unit of the plurality of mixing units:(a) the first gap defines a first distance in the second direction, (b) a distance in the second direction between an edge of the first rib and a projection of an edge of the fourth rib onto the first rib in a direction opposite the first direction defines a second distance,(c) a distance in the first direction between the first rib and the fourth rib defines a third distance,(d) the second distance is greater than the first distance, and(e) the first distance and the third distance are approximately equal.

6. The heat exchange apparatus of any one of claims 1-5, wherein the ribs extend from the interior surface in a third direction that is orthogonal to the first direction and the second direction.

7. The heat exchange apparatus of claim 6, wherein the first side of the body comprises a first surface that is planar and offset from the interior surface in the third direction, the cavity opening to the first surface.

8. The heat exchange apparatus of claim 7, wherein the interior surface comprises a maj or surface portion that is planar and oriented normal to the third direction, the ribs extending from the major surface portion.

9. The heat exchange apparatus of claim 8, wherein the interior surface comprises a minor surface portion that surrounds the major surface portion and extends in the third direction from the major surface portion to the first surface.SP25-01310. The heat exchange apparatus of any one of claims 7-9, wherein a height of the ribs from the interior surface in the third direction is less than the offset of the first surface from the interior surface in the third direction.

11. The heat exchange apparatus of claim 8 or claim 9, wherein a height of the ribs from the major surface portion in the third direction is less than the offset of the first surface from the major surface portion in the third direction.

12. The heat exchange apparatus of any one of claims 7-11, further comprising a groove in the first surface, the groove surrounding the interior surface with a portion of the first surface on each side of the groove.

13. The heat exchange apparatus of any one of claims 1-12, wherein the body has a platelike shape comprising a length, a width, and a thickness that is less than the length and less than the width.

14. The heat exchange apparatus of any one of claims 1-13, wherein the rows of the ribs are parallel to one another.

15. The heat exchange apparatus of any one of claims 1-14, wherein one or more of (i) the rows of the ribs comprise at least 10 rows of the ribs and (ii) the ribs within each row comprise at least 5 ribs per row.

16. A flow reactor module, comprising:a first process fluid module with a process fluid passage extending therethrough, the first process fluid module comprising an extended body having a width, a length, and a thickness that is less than the width and less than the length, the first process fluid module having a first major surface and a second major surface disposed on opposite sides of the first process fluid module;a first heat exchange apparatus sealed against the first major surface of the first process fluid module, the first heat exchange apparatus comprising:a body having a first side with an interior surface that defines a cavity configured to contain heat exchange fluid against the first major surface of the first process fluid module,SP25-013a plurality of ribs extending from the interior surface to define a heat exchange fluid path for the heat exchange fluid, the ribs arranged in multiple rows that are spaced from one another in a first direction,at least one inflow port extending through the body and opening to the cavity through the interior surface, the at least one inflow port configured to deliver the heat exchange fluid to the heat exchange fluid path, andat least one outflow port extending through the body and opening to the cavity through the interior surface, the at least one outflow port configured to receive the heat exchange fluid from the heat exchange fluid path, the at least one outflow port spaced from the at least one inflow port in the first direction,wherein the ribs are elongate in a second direction that is orthogonal to the first direction, the ribs within each row being spaced from one another in the second direction so as to define a gap between adjacent ribs, andwherein the ribs within each successive row are offset along the second direction relative to the ribs within a preceding row such that most of the gaps in the preceding row, when projected in the first direction, intersect a respective rib in the successive row.

17. The flow reactor module of claim 16, wherein each rib of the plurality of ribs of the first heat exchange apparatus has an aspect ratio between a length of the rib in the second direction and a width of the rib in the first direction, and wherein the aspect ratio of most of the ribs is at least 15.

18. The flow reactor module of claim 16 or claim 17, wherein the first major surface and the second major surface of the first process fluid module are oriented perpendicularly to a third direction that is orthogonal to the first direction and the second direction and corresponds the thickness of the first process fluid module, and wherein there is a clearance between the ribs of the first heat exchange apparatus and the first major surface of the first process fluid module.SP25-01319. The flow reactor module of claim 18, wherein:(i) the ribs of the first heat exchange apparatus define a plurality of mixing units, each mixing unit comprising:(a) in the preceding row, a first rib, a second rib adjacent to the first rib in the second direction, and a first gap between the first rib and the second rib, and(b) in a successive row spaced from the preceding row in the first direction, a third rib, a fourth rib adjacent to the third rib in the second direction, a second gap between the third rib and the fourth rib, a fifth rib adjacent to the fourth rib in the second direction, and a third gap between the fourth rib and the fifth rib,(ii) within each mixing unit of the plurality of mixing units:(a) the first gap defines a first distance (dl) in the second direction,(b) a length in the second direction between an edge of the first rib and a projection of an edge of the fourth rib (closest to the edge of the first rib) onto the first rib in a direction opposite the first direction defines a second distance (d2),(c) a spacing in the first direction between the first rib and the third rib defines a third distance (d3),(d) the second distance (d2) is greater than the first distance (dl), and(e) the first distance (dl) and the third distance (d3) are approximately equal.

20. The flow reactor module of claim 19, wherein, within each mixing unit of the plurality of mixing units:a first portion of the heat exchange fluid is configured to flow through the first gap in the first direction towards a first side of the fourth rib, the first portion having a first pressure measured proximate the first side,a second portion of the heat exchange fluid is configured to impinge upon the first side of the fourth rib and flow laterally towards the second gap between the third rib and the fourth rib or the third gap between the fourth rib and the fifth rib, the second portion having a second pressure measured proximate the second gap or the third gap,a third portion of the heat exchange fluid is configured to flow in the first direction through the clearance between the fourth rib and the first major surface, the third portion having a third pressure measured proximate a second side of the fourth rib that is opposite the first side, anda relationship among the first pressure, the second pressure, and the third pressure follows the equation: Pl - P2 > Pl - P3.SP25-01321. The flow reactor module of any one of claims 18-20, wherein the ribs of the first heat exchange apparatus extend from the interior surface in the third direction.

22. The flow reactor module of any one of claims 18-21, wherein the body of the first heat exchange apparatus comprises a first surface that is planar and offset from the interior surface in the third direction, the first surface configured to receive a seal that surrounds the interior surface and abuts the first major surface of the first process fluid module.

23. The flow reactor module of any one of claim 18-22, wherein the interior surface of the first heat exchange apparatus comprises a major surface portion that is planar and oriented normal to the third direction, the ribs extending from the major surface portion.

24. The flow reactor module of any one of claims 16-23, wherein the rows of the ribs of the first heat exchange apparatus are parallel to one another.

25. The flow reactor module of any one of claims 16-24, wherein one or more of (i) the rows of the ribs of the first heat exchange apparatus comprise at least 10 rows of the ribs and (ii) the ribs within each row comprise at least 5 ribs per row.

26. The flow reactor module of any one of claims 16-25, further comprising a second heat exchange apparatus sealed against the second major surface of the first process fluid module, the second heat exchange apparatus configured in substantially the same manner as the first heat exchange apparatus.

27. The flow reactor module of any one of claims 16-25, further comprising a second process fluid module configured in substantially the same manner as the first process fluid module, the second process fluid module spaced from the first process fluid module in a fourth direction that is orthogonal to the first direction and the second direction, wherein:the second major surface of the second process fluid module faces the first major surface of the first process fluid module,the body of the first heat exchange apparatus has a second side opposite the first side, the second side having a second interior surface, a second cavity, and a second plurality of ribsSP25-013that are symmetrical about a symmetry plane to the interior surface, the cavity, and the plurality of ribs, respectively, on the first side of the body,wherein the at least one inflow port and the at least one outflow port extend in the fourth direction and open to the second cavity through the second interior surface, andthe second side of the first heat exchange apparatus is sealed against the second major surface of the second process fluid module to contain the heat exchange fluid against the second major surface.

Images