Microreactor Mixing Unit Geometry for Low Pressure Drop
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Solution Overview
Problem
Existing microreactors suffer from inefficient mixing due to energy loss, increased pressure drop, and ineffective mixing regions caused by the folded line-shaped profiles and outlet structures, leading to poorer mixing efficiency and longer mixing times.
Innovation Solution
The microreactor design incorporates auxiliary flow-guiding portions and a first blocking portion with specific geometric configurations to enhance fluid impact and reduce ineffective mixing regions, featuring symmetrically arranged passages with constant cross-sections and expansion passages to promote turbulent mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a folded line-shaped profile is used for the outer contour of mixing units, then the microreactor can be manufactured with simple channel structures, but energy loss increases and pressure drop increases
Solution Approach 1:
The outer contour is divided into multiple mixing units with sequential connections, each having its own blocking portions and passages. This segmentation allows the fluid to be divided into multiple streams that can be mixed independently, reducing the overall energy loss while maintaining manufacturing simplicity.
Solution Approach 2:
The patent introduces auxiliary flow-guiding portions that extend in the longitudinal direction from the side profiles, creating a third dimension of flow control. This adds flow guidance capability without complicating the basic folded line-shaped profile structure, reducing energy loss while maintaining manufacturing simplicity.
2Device complexity
If a folded line-shaped profile is used for the outer contour, then the microreactor structure is simplified, but mixing efficiency decreases due to larger ineffective mixing regions
Solution Approach 1:
Each mixing unit is segmented into distinct regions: advancing passages, mixing regions, and blocking portions. This segmentation creates multiple independent mixing zones that reduce ineffective mixing regions while maintaining overall structural simplicity.
Solution Approach 2:
The patent applies different geometric characteristics to different regions: the advancing passages have constant cross-sections for efficient flow, while the mixing regions have specific geometric configurations to enhance mixing. The auxiliary flow-guiding portions are strategically positioned to optimize local flow patterns without complicating the overall structure.
3Ease of manufacture
If the outlet is designed as a straight passage with constant cross-section, then the manufacturing is simplified, but fluid backtracking occurs increasing pressure drop
Solution Approach 1:
The outlet passage is designed with varying cross-sectional dimensions along its length, creating dynamic flow characteristics that prevent fluid backtracking. The cross-section changes from the advancing passage through the mixing region to the outlet, optimizing flow direction and reducing pressure drop while maintaining manufacturing simplicity.
4Productivity
If multiple mixing units are connected in sequence to achieve effective mixing, then mixing efficiency improves, but pressure drop increases significantly
Solution Approach 1:
The microreactor is divided into multiple mixing units, each capable of independent mixing operations. This segmentation allows parallel processing of fluid streams, achieving effective mixing with fewer units and reduced cumulative pressure drop.
Solution Approach 2:
The auxiliary flow-guiding portions extend in the longitudinal direction, creating additional flow paths and mixing opportunities without increasing the number of sequential mixing units. This dimensional addition enhances mixing efficiency while controlling pressure drop.
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 improved design achieves enhanced mixing efficiency with reduced pressure drop, shorter mixing times, and increased flux, allowing for more uniform and controllable chemical reactions with reduced by-products.
Implementation Method 1
the auxiliary flow-guiding portions being configured so that the fluid in the first advancing passage and that in the second advancing passage flow towards each other into the mixing region and impact on each other
Implementation Method 2
a first blocking portion arranged within the flow chamber, so that in the flow chamber a first advancing passage is defined by a first side profile of the housing and the first blocking portion, a second advancing passage is defined by a second side profile of the housing opposite the first side profile and the first blocking portion
Data Source
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AI summary
The present invention discloses a microreactor (300), which comprises a plurality of mixing units (310) connected in sequence along a longitudinal direction, each of the mixing units (310) comprising a housing (350) in which a flow chamber (330) is formed. An inlet portion (320) and an outlet portion (322) formed on two opposite ends of each mixing unit (310) along the longitudinal direction, respectively, are in communication with the flow chamber (330). The mixing unit (310) further comprises a first blocking portion (311) centrally arranged within said flow chamber (330) along a lateral direction perpendicular to the longitudinal direction, and between the inlet portion (320) and the outlet portion (322), so that a first advancing passage (317), a second advancing passage (318) and a mixing region (319) are formed within the flow chamber (330). The first advancing passage (317) and the second advancing passage (318) are in communication with the mixing region (319). At downstream ends of said first advancing passage (317) and said second advancing passage (318), the microreactor (300) is further provided with auxiliary flow-guiding portions (316) protruding from a first side profile (352) and a second side profile (354) respectively and extending towards but spaced apart from each other.