Porous Flow Reactor Modules for Uniform Scale-Up
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Solution Overview
Problem
Existing fluidic systems face challenges in maintaining uniform fluid flow rates and flux across transverse cross-sections, particularly when scaled up, leading to non-uniform distribution and potential redesign requirements.
Innovation Solution
The development of fluidic systems with modules configured for uniform time-averaged linear flow rate and flux, utilizing porous layers with varying pore diameters and interconnected internal volumes, allowing for scalable design without significant chemical process adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fluidic systems are scaled up to increase production capacity, then productivity improves, but flow uniformity deteriorates
Solution Approach 1:
The patent employs porous layers with specifically controlled pore sizes and distributions to regulate fluid flow. The porous structure creates capillary forces that distribute fluid uniformly across the cross-section, preventing channeling and ensuring consistent flow rates even in scaled-up systems with large transverse dimensions.
Solution Approach 2:
The patent utilizes changes in physical parameters including pore diameter, porosity, and surface tension to control flow distribution. By adjusting these parameters across different zones or layers, the system maintains uniform flow characteristics while accommodating larger overall dimensions for increased productivity.
2Device complexity
If module size is increased to reduce the number of components, then device complexity decreases, but flow uniformity deteriorates
Solution Approach 1:
The patent divides the fluidic system into multiple functional layers (porous layers, non-porous layers, reaction zones) that work together within a single integrated module. This segmentation allows each layer to perform a specific function in maintaining flow uniformity while the overall module remains compact and avoids the need for multiple separate components.
Solution Approach 2:
The patent transitions from two-dimensional flow distribution to three-dimensional flow control by incorporating vertical layering with porous and non-porous structures. This dimensional approach enables uniform flow distribution across large cross-sectional areas within a single module volume, eliminating the need for multiple planar components.
3Productivity
If transverse cross-sectional area is increased to improve flow capacity, then productivity improves, but flow rate uniformity deteriorates
Solution Approach 1:
The patent employs porous layers with specifically controlled pore sizes and distributions to regulate fluid flow. The porous structure creates capillary forces that distribute fluid uniformly across the cross-section, preventing channeling and ensuring consistent flow rates even in scaled-up systems with large transverse dimensions.
Solution Approach 2:
The patent implements different pore size distributions and porosity values in different regions or layers of the module. This local variation in material properties allows optimization of flow distribution in specific zones, ensuring uniform flow rates across the entire large cross-sectional area while maintaining high overall flow 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
Enables uniform fluid flow across large transverse cross-sectional areas, facilitating easy scale-up and maintaining consistent flow characteristics, reducing the need for redesign and enhancing reaction efficiency.
Implementation Method 1
the first layer comprises pores having a first average diameter, the second layer comprises pores having a second average diameter
Data Source
AI summary
Fluidic systems, modules, and associated methods are generally described. In some embodiments, a fluidic system comprises a module which is configured such that fluid may flow therethrough with a relatively uniform time-averaged linear flow rate (i.e., the time-averaged flow rate that is perpendicular to the transverse cross-sectional area) and/or time-averaged flux across the transverse cross-sectional area of the module. Advantageously, such modules may behave in a way such that the time-averaged linear flow rate and/or time-averaged flux exhibits minimal or no dependence on the transverse cross-sectional area thereof. This may allow for modules to be scaled-up in a relatively facile manner by merely increasing the transverse cross-sectional area, which may eliminate or substantially reduce the need for other components of the module to be redesigned upon scale-up. In some embodiments, modules may be scaled-up in a manner that requires no or minimal chemical process adjustments.