Modular Flow Reactor for Solid Catalyst Handling
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Solution Overview
Problem
Current reactor systems for flow reactions are not easily adaptable for handling solid catalysts and operating at high pressures, making them inefficient for rapid catalyst changes and requiring significant effort.
Innovation Solution
A reactor system comprising two blocks, two intermediate layers, and a pressing device, where one intermediate layer includes a sealing layer and a channel structure element with a reaction channel, allowing for a meandering channel design and easy assembly/disassembly, enabling the use of catalyst films and precise temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional reactor systems are used for flow reactions, then the reaction process can be maintained, but the system is not easily adaptable for handling solid catalysts and operating at high pressures, making catalyst changes time-consuming and labor-intensive
Solution Approach 1:
The reactor system is divided into separate modular components including a reactor body, catalyst carrier, and sealing elements. The catalyst carrier can be independently removed and replaced without disassembling the entire reactor system, enabling rapid catalyst changes while maintaining high pressure operation capability and solid catalyst compatibility.
2Ease of operation
If conventional reactor systems are used, then the basic reaction function is maintained, but the system requires significant effort for catalyst changes and lacks ease of operation
Solution Approach 1:
The reactor system incorporates a dynamic sealing mechanism that automatically maintains sealing when the catalyst carrier is inserted or removed. The sealing element is positioned to engage with the reactor body opening, providing automatic sealing action that simplifies operation while managing the mechanical complexity of the movable catalyst carrier.
3Productivity
If high pressure operation is implemented, then reaction efficiency is improved, but the system requires robust sealing and structural integrity
Solution Approach 1:
The sealing element is pre-positioned and configured to engage with the reactor body opening before high pressure operation begins. The catalyst carrier is designed with features that ensure proper sealing engagement is established in advance, maintaining sealing integrity when high pressure conditions are applied during the reaction process.
Data Source
Figure 1
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AI summary
The invention relates to a reactor system for continuous flow reactions, which comprises at least two blocks (1, 2), two intermediate layers (8, 9) and a pressure application device, as well as at least one supply line (10) and one discharge line (11), the first block (1), the intermediate layers (8, 9) and the second block (2) forming a stack-like assembly which is fixed with the pressure application device. The reactor system is characterised in that at least one intermediate layer comprises a seal layer (8) and one intermediate layer comprises a duct structure element (9) containing a reaction duct, wherein the supply line (10) is operatively connected to the input side of the reaction duct, and the discharge line (11) is operatively connected to the output side of the reaction duct, and the stack-like assembly is detachable.