Modular Microreactor Plate Grooves for Mixing and Thermal Control
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Solution Overview
Problem
Existing microreactor technologies face challenges in modular design and efficient mixing of reactants, particularly in achieving thorough mixing and controlling temperature levels across different modules, which limits their scalability and efficiency in chemical reactions.
Innovation Solution
A modular microreactor system comprising plate bodies with groove-shaped depressions for reaction tubes, allowing for thermal transfer media guidance and modular assembly, along with cross-sectional constrictions and enlargements in reaction tubes to enhance mixing, and integration of fluid mixers and sensors for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If microreactors are constructed in a modular manner using small diameter tubes, then scalability and flexibility are improved, but mixing efficiency and temperature control deteriorate
Solution Approach 1:
The reactor is divided into modular plate bodies that can be assembled in series, with each plate containing multiple reaction channels. This segmentation allows flexible scaling while maintaining efficient mixing through the inherent design of each modular unit.
Solution Approach 2:
The invention transitions from traditional small-diameter tubular reactors to plate-shaped reaction chambers with larger surface areas. This dimensional change from 1D tubes to 2D plates enables improved heat and mass transfer while maintaining modular scalability.
2Device complexity
If traditional tubular reactors are used, then simplicity of design is improved, but heat transfer efficiency and mixing performance deteriorate
Solution Approach 1:
The reaction channels and thermal transfer channels are merged into a single plate body structure, with reaction channels formed as grooves directly in the plate. This integration simplifies the overall design while dramatically improving heat transfer efficiency compared to separate tubular systems.
Solution Approach 2:
The invention replaces 1D tubular reaction paths with 2D planar reaction channels in plates, increasing the heat transfer surface area and improving temperature control while maintaining design simplicity through the integrated plate structure.
3Temperature
If plate bodies with groove-shaped depressions are used, then thermal transfer efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The plate bodies incorporate sintered metal structures that provide both mechanical strength and efficient thermal transfer pathways. The sintering process naturally creates porous structures that enhance heat transfer while the modular plate design keeps manufacturing relatively simple.
Solution Approach 2:
The invention uses sintering parameters to create plates with optimized pore structures for thermal transfer. By controlling sintering temperature, pressure, and material composition, the plates achieve high thermal efficiency while maintaining ease of manufacture through a single-step sintering process.
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
Enables efficient mixing and temperature control across multiple modules, promoting turbulent flow and efficient chemical reactions, while allowing for flexible and scalable reactor design.
Implementation Method 1
cross-sectional constrictions and enlargements in reaction tubes to enhance mixing, and integration of fluid mixers
Implementation Method 2
groove-shaped depression in which a reaction tube is accommodated... allowing for thermal transfer media guidance
Data Source
AI summary
Modular microreactors are provided composed of microreactor parts including a plate body which has, on one plate side, a groove-shaped depression in which a reactor tube is accommodated, and the reaction tube has connection ends on the outer sides of the plate body. Also disclosed are reaction tubes for turbulent mixing, kits for producing the reactors and the use thereof for commencing chemical reactions.