Micro-reactor Channel Plugging Prevention via Ultrasonic Coupling
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Solution Overview
Problem
In micro-reactor continuous-reaction technology, plugging of channels due to by-products is a significant issue, especially at confluence and mixing areas, leading to increased pressure and reduced yield, which is costly to prevent using dry feeds and drying procedures, as they are expensive and sometimes dangerous.
Innovation Solution
The method involves generating ultrasonic waves within the channel-system using a process fluid to prevent or remove plugging by guiding the waves through plugging-susceptible areas, using piezo-electric transducers to couple the energy into the fluid flow, allowing for higher water content and reducing the risk of standing wave formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dry feeds are used to prevent plugging, then plugging is avoided, but cost increases and safety risks arise due to expensive and sometimes dangerous drying procedures
Solution Approach 1:
The invention extracts and removes the harmful by-products (precipitates) from the reaction mixture using a separating agent that forms a second phase. This allows the use of non-dry feeds without plugging, as the by-products are continuously removed rather than prevented by drying the feeds beforehand
Solution Approach 2:
A separating agent is introduced as an intermediary substance that mediates between the reaction mixture and the by-products. This agent forms a second phase that selectively solubilizes or suspends the precipitates, allowing them to be separated and removed without requiring expensive drying procedures
2Reliability
If drying procedures are applied to prevent plugging, then channel plugging is avoided, but operational complexity and cost increase significantly
Solution Approach 1:
The harmful by-products are extracted from the reaction mixture by introducing a separating agent that creates a second phase. This continuous extraction process prevents plugging without requiring complex drying equipment or procedures
Solution Approach 2:
The invention uses fluid dynamics and phase separation principles to remove by-products. The separating agent creates a second liquid phase that carries away precipitates through the reaction channel, using hydraulic principles rather than mechanical drying equipment
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
This approach effectively prevents plugging without the need for dry feeds or hazardous drying processes, maintaining reactor efficiency and safety while allowing for higher water content, up to 500 ppm, thereby reducing operational costs and ensuring continuous reactor operation.
Implementation Method 1
generating at least one ultrasonic wave travelling through the channel-system by coupling in a flow direction of at least one process fluid of a plurality of process fluids the at least one ultrasonic wave into the at least one process fluid
Implementation Method 2
using piezo-electric transducers to couple the energy into the fluid flow
Data Source
AI summary
A method for preventing plugging of a continuous-reaction channel-system caused by a by-product of a continuous-reaction being carried out in said channel-system comprises the step of generating at least one ultrasonic wave travelling through said channel-system by coupling in a flow direction of at least one process fluid of a plurality of process fluids said at least one ultrasonic wave into said at least one process fluid.