Microreactor Stirring Device for Viscous Fluid Processing
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Solution Overview
Problem
Microreactors face challenges in scaling up and efficiently processing fluids, especially those with high viscosity or involving solid separation or gas generation, due to limitations in controlling the dissolution and dispersion states of fluids and maintaining stable thin film conditions, leading to issues like clogging and non-uniform reactions.
Innovation Solution
A fluid processing apparatus with rotating processing surfaces and a cylindrical stirring space equipped with a stirring blade and screen, allowing for precise control of shear force and energy addition to the fluid before introduction into the circular flow path, enabling stable thin film formation and homogeneous reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a microchannel is used in a microreactor, then the reaction rate and energy efficiency are improved, but the ability to process viscous substances and handle solid separation or gas generation is deteriorated
Solution Approach 1:
The patent changes the flow path geometry from a linear microchannel to a circular flow path between rotating processing surfaces. This parameter change allows the system to maintain high reaction rates while accommodating viscous substances and solid-gas reactions through the circular motion and adjustable clearance between surfaces.
Solution Approach 2:
The patent introduces dynamic rotating processing surfaces that can adjust their relative position and speed. This dynamic capability enables the system to handle different substance viscosities and reaction types by varying the rotation speed and clearance, thereby improving versatility while maintaining productivity.
2Device complexity
If fluids are introduced into the circular flow path without preliminary stirring, then the device complexity is reduced, but the homogeneity of fluid dissolution and dispersion is deteriorated
Solution Approach 1:
The patent merges the stirring function with the reaction vessel by incorporating a stirring blade directly into the circular flow path structure. This combination eliminates the need for separate stirring equipment while ensuring homogeneous fluid dissolution and dispersion before reactions occur.
Solution Approach 2:
The circular flow path structure itself provides the stirring action through its rotation, making the system self-sufficient. The rotating processing surfaces automatically mix and disperse fluids as they move through the circular path, eliminating the need for external stirring mechanisms.
3Manufacturing precision
If the clearance between processing surfaces is kept very narrow to form a forced thin film, then the reaction uniformity is improved, but the risk of clogging and instability is increased
Solution Approach 1:
The patent uses dynamic rotating processing surfaces with adjustable clearance to maintain stable thin film formation. The rotation creates centrifugal forces that prevent clogging while the adjustable clearance allows optimization of film thickness for uniform reactions, resolving the contradiction between precision and reliability.
4Productivity
If scaling-up is attempted in a microreactor, then the production capacity is increased, but the flow path stability and reaction uniformity are deteriorated
Solution Approach 1:
The patent segments the reaction system into multiple identical circular flow path units that can operate in parallel. Each unit maintains the stable thin film conditions and reaction uniformity of a small-scale microreactor, while the combined output of multiple segments achieves large-scale production capacity.
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 allows for improved homogeneity and stability of fluid processing, reducing clogging and non-uniformity, enabling efficient processing of viscous substances and polymers, and achieving uniform reaction products with controlled particle diameters.
Implementation Method 1
a stirring blade; and a screen, in the stirring space, wherein a stirring energy is added by the stirring blade to the fluid to be processed that is immediately before being introduced into the circular flow path
Implementation Method 2
the fluid to be processed that is applied with a pressure by a fluid pressure imparting mechanism is made to pass through a circular flow path formed between the processing surfaces which are disposed in a position they are faced with each other so that the fluid to be processed is processed under the state of the thin film fluid
Data Source
AI summary
Provided are an immediately-before-stirring-type fluid processing device and an immediately-before-stirring-type fluid processing method that can adjust or improve the final properties of a fluid to be processed that is introduced as a raw material into an annular flow channel of a microreactor employing the annular flow channel, which is formed between relatively rotating processing surfaces, as a flow channel in which fluid processing is performed. A fluid to be processed, which has been prepared in a fluid preparing system so as to be in an ideal state for reaction, is charged into a fluid processing device. The fluid processing device subjects the fluid to be processed to reaction processing in an annular flow channel, which is formed between two processing surfaces. A cylindrical stirring space is provided in the radially inner side of the annular flow channel, and a rotor and a screen are disposed inside the stirring space. Stirring energy is applied by the rotor and a shearing force is applied between the rotor and the screen to the fluid to be processed immediately before the fluid to be processed is introduced into the annular flow channel.