Structured Microreactor Ozonolysis for High Space-Time Yield
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Solution Overview
Problem
Conventional ozonolysis processes face challenges with space-time yield and selectivity, leading to uneven temperature loads, product quality issues, safety risks due to unstable ozonation products, and significant gas circulation and pollution, which limits ozone concentration and increases energy and economic burdens.
Innovation Solution
The process employs a structured microreaction system with two reaction zones and a cooling zone, allowing for controlled ozonolysis and oxidative or reductive cleavage of ozonization products in a series of microreactors, enhancing heat and mass transfer, and enabling higher ozone concentrations while ensuring safety by operating below explosion limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional reactors are used for ozonolysis, then the process is simple to operate, but space-time yield and selectivity are poor
Solution Approach 1:
The reactor is divided into multiple channels with different depths (20-1800 μm) arranged in parallel, allowing simultaneous optimization of heat transfer and residence time distribution. This segmentation enables higher space-time yields while maintaining operational simplicity through modular design.
Solution Approach 2:
The invention transitions from conventional macro-scale reactors to micro-scale channels, utilizing the micro-dimension to achieve enhanced heat and mass transfer coefficients. This dimensional change fundamentally improves productivity without requiring complex control systems.
2Temperature
If conventional reactors are used, then device complexity is low, but temperature control is poor leading to hot spots
Solution Approach 1:
The reactor channels are segmented into multiple parallel pathways with controlled depths, creating numerous heat transfer interfaces. This segmentation distributes heat generation across many small surfaces, preventing hot spots while maintaining relatively simple overall structure.
Solution Approach 2:
Different channel depths are implemented to create localized heat transfer characteristics. Deeper channels provide longer residence time while shallower channels enhance heat dissipation, allowing each region to optimize for its specific functional requirement.
3Productivity
If ozone concentration is increased to improve productivity, then space-time yield increases, but safety risks increase due to explosive decomposition
Solution Approach 1:
The reactor is segmented into multiple parallel channels, allowing the system to handle high ozone concentrations safely by distributing the reaction across many small pathways. This segmentation prevents accumulation of unstable intermediates and reduces the risk of explosive decomposition.
Solution Approach 2:
The invention changes the physical parameters of the reactor (channel depth, cross-section) to optimize the relationship between ozone concentration, residence time, and heat transfer. These parameter changes enable safe operation at higher ozone concentrations by controlling the reaction kinetics and heat generation rates.
4Productivity
If higher ozone concentrations are used, then productivity improves, but by-product formation increases
Solution Approach 1:
Different channel depths create localized reaction conditions that optimize selectivity. Shallower channels provide better heat transfer and shorter residence times, reducing the formation of unwanted by-products while deeper channels maintain higher conversion rates.
Solution Approach 2:
The reactor design changes physical parameters to control reaction kinetics, allowing operation at higher ozone concentrations while maintaining selectivity. The optimized channel geometry controls mass transfer rates and residence times to minimize by-product formation.
5Reliability
If conventional reactors are used, then construction is simple, but heat dissipation is insufficient leading to safety risks
Solution Approach 1:
The reactor structure is segmented into multiple parallel channels with varying depths, creating extensive heat transfer surfaces. This segmentation provides superior heat dissipation capacity without requiring complex external cooling systems, as the heat is distributed across numerous internal interfaces.
Solution Approach 2:
The channel depth is varied locally to optimize heat dissipation characteristics. Deeper channels provide longer heat transfer paths while shallower channels provide better thermal contact, creating a distributed heat management system that enhances safety.
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 significantly improves space-time yields and selectivities, reduces by-product formation, simplifies downstream processing, and allows for higher ozone concentrations, thereby enhancing product quality and reducing energy and economic burdens.
Implementation Method 1
the significantly improved removal of the reaction heat due to the high surface-to-volume ratio
Implementation Method 2
the significantly improved removal of the reaction heat due to the high surface-to-volume ratio as well as the defined flow regimes
Implementation Method 3
In the first part of the reaction, a gas/liquid reaction of ozone with the olefinic feedstock, ozonides are formed
Implementation Method 4
During oxidative ozonolysis, in which the intermediate ozonation products are oxidized, ketones or carboxylic acids are formed
Implementation Method 5
If the intermediate products are cleaved by reducing means, aldehydes are obtained
Data Source
AI summary
The invention relates to a process for the ozonolysis of unsaturated feedstocks, which is characterized by the fact that the reaction is carried out in a structured reactor.