Continuous Flow Reactor Geometry for Clog-Free Solid-Liquid Mixing
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Solution Overview
Problem
Existing continuous flow reactors are limited in their ability to handle solids as reactants, products, or by-products due to clogging issues and require moving parts, restricting their use to low solid concentrations and specific types, and they lack efficient mixing and heat transfer capabilities.
Innovation Solution
A continuous flow reactor with a unique geometry and angled cavities, featuring a jacket for heating/cooling, and no moving parts, allowing for efficient mixing and handling of a wide range of solid concentrations and types without clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flow reactors are used for solid-liquid reactions, then high heat transfer area and efficient mixing are achieved, but clogging occurs and solids handling is limited to low concentrations
Solution Approach 1:
The reactor is divided into multiple cavities with varying volumes arranged in series, creating a segmented flow path that progressively handles increasing solid concentrations without clogging. Each cavity acts as an independent mixing and reaction zone, allowing solids to be gradually accommodated throughout the system.
Solution Approach 2:
The invention transitions from traditional linear flow paths to a three-dimensional cavity-based structure with varying volumes. This dimensional change allows the reactor to handle solids suspension more effectively by providing multiple flow paths and residence time zones within the same reactor volume.
2Adaptability or versatility
If moving parts are added to handle solids in flow reactors, then solids handling capability is improved, but device complexity and maintenance needs increase
Solution Approach 1:
The reactor uses the flow of liquid itself to suspend and transport solids through the cavity system, eliminating the need for external moving parts like pumps or agitators. The varying cavity volumes create natural flow patterns that keep solids suspended and moving forward without mechanical intervention.
Solution Approach 2:
The invention replaces mechanical systems (moving parts, agitators, pumps) with a fluid-dynamic system based on varying cavity volumes. The liquid flow regime, controlled by the cavity geometry, substitutes for mechanical energy input to achieve solids suspension and transport.
3Ease of manufacture
If traditional reactor geometries are used, then manufacturing is simplified, but mixing efficiency and heat transfer for solids are insufficient
Solution Approach 1:
Different cavities within the reactor have different volumes and geometries optimized for their specific function in the flow path. Early cavities have smaller volumes for initial mixing, while later cavities have larger volumes for handling higher solid concentrations, creating local quality variations that enhance overall productivity.
Solution Approach 2:
The cavities are designed with asymmetric geometries rather than uniform shapes, allowing optimized flow patterns and mixing characteristics in each section. This asymmetry enables better adaptation to solid-liquid reaction requirements while remaining manufacturable using standard techniques.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The reactor facilitates high-throughput, efficient mixing, and effective heat exchange for solid-liquid reactions, supporting a wide range of solid concentrations and types, while minimizing maintenance needs.
Implementation Method 1
a jacket covering around the cavities to provide heating or cooling effect as per the requirement
Data Source
AI summary
A continuous flow reactor without any moving parts to facilitate solid-liquid reaction without clogging is disclosed herein. It comprises plurality of identical cavities in series/sequence, each cavity being provided with: a pair of inlets at the top to allow entry of reactants into the reactor; an outlet at the bottom to allow the reactants to the next cavity for mixing; and a jacket covering around the cavities to provide heating or cooling effect as per the requirement. The outlet of the previous cavity is inclined at a suitable angle relative to the outlet of the next cavity to prevent clogging and facilitate efficient mixing of the reactants.