Modular Continuous Flow Photoreactor with Replaceable LED Lighting
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Solution Overview
Problem
Existing photoreactors face inefficiencies in product yield and time due to fixed light absorption depth, rigid processing parameters, and complex component replacement processes, which limit throughput and increase costs and labor costs in batch configurations, while continuous flow systems struggle with component replacement and equipment costs.
Innovation Solution
A continuous flow photoreactor design with easily replaceable and adjustable components, including a reactor flow system, a lighting system using LEDs for controlled wavelength, and a temperature control system to manage heat, allowing for flexible operation and reduced downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional fixed plate-based photoreactor components are used, then structural stability is maintained, but component replacement becomes expensive and time-consuming
Solution Approach 1:
The photoreactor is divided into separate modular components including reactor vessels, lighting assemblies, and temperature control systems that can be independently removed and replaced without shutting down the entire system, resolving the contradiction between structural stability and ease of component replacement
Solution Approach 2:
The system transitions from fixed static components to dynamically replaceable modules with quick-connect interfaces, allowing components to be swapped during operation without prolonged shutdowns, thus improving ease of repair while minimizing time loss
2Productivity
If adjustable light intensity and wavelength are implemented, then reaction efficiency improves, but device complexity increases
Solution Approach 1:
The lighting system uses LED arrays with adjustable intensity and interchangeable filters to modify wavelength, allowing reaction efficiency to be optimized without requiring complex optical systems, thus improving productivity while keeping device complexity manageable
Solution Approach 2:
A single lighting assembly serves multiple functions by combining adjustable intensity control with interchangeable wavelength filters, enabling one component to achieve what would otherwise require multiple separate systems, thereby improving reaction efficiency without proportionally increasing device complexity
3Productivity
If continuous flow system is used, then throughput increases, but component replacement difficulty increases
Solution Approach 1:
The continuous flow photoreactor is segmented into independently replaceable modules including flow cells, lighting assemblies, and temperature control units that can be swapped without shutting down the continuous flow system, thus maintaining high throughput while improving component replacement ease
Solution Approach 2:
The system employs dynamic modular architecture where components are designed for quick replacement during continuous operation, allowing maintenance and adjustments without interrupting the continuous flow process, thereby preserving throughput while enhancing ease of repair
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
Enhances product yield and reduces operational costs by enabling adjustable light intensity and wavelength, improving reaction efficiency, and simplifying component replacement, thereby increasing the photoreactor's operational flexibility and reducing downtime.
Implementation Method 1
The lighting system includes a light emitting apparatus (e.g., a plurality of LEDs) configured to emit light in a defined wavelength range toward the length of reactor tubing
Implementation Method 2
The temperature control system can be configured to circulate a fluid to cool the lighting system
Data Source
AI summary
Embodiments described herein relate generally to continuous flow photoreactors with easily replaceable and adjustable components. The photoreactor includes a reactor flow system, a lighting system, and a temperature control system. The reactor flow system includes a reactor inlet port, a reactor outlet port, and a length of reactor tubing fluidically coupled to the reactor inlet port and reactor outlet port. The lighting system includes a light emitting apparatus (e.g., a plurality of LEDs) configured to emit light in a defined wavelength range toward the length of reactor tubing. The temperature control system includes an inlet port, an outlet port, and a length of temperature control tubing fluidically coupled to the inlet port and the outlet port. In some embodiments, the temperature control system can be configured to circulate a fluid to cool the lighting system.