Chemical Reactor Heat Exchange Circuit with Interleaved Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current devices for chemical reactors lack effective means for heat exchange, leading to inefficient reaction processes and thermal runaway issues, and are difficult to produce industrially due to complex geometries and material limitations.
Innovation Solution
A device with a mixing circuit and an interleaved heat exchange circuit, where the heat exchange circuit is closely integrated with the mixing circuit, allowing for efficient thermal management and production through a welding-diffusion process using superposed plates and hot isostatic pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a complex three-dimensional structure with bends and bifurcations is used for intimate mixing, then mixing efficiency is improved, but manufacturing difficulty increases and industrial production becomes difficult
Solution Approach 1:
The device is divided into multiple superposed plates, each containing portions of the mixing circuit and heat exchange circuit. This segmentation allows complex three-dimensional structures to be manufactured as simpler two-dimensional plate patterns that are then assembled together, making industrial production feasible while maintaining efficient mixing characteristics.
2Temperature
If heat exchange circuit is arranged close to mixing circuit for efficient thermal management, then heat exchange efficiency is improved, but structural complexity increases
Solution Approach 1:
The mixing circuit and heat exchange circuit are merged into a single integrated device structure where the heat exchange circuit is arranged in close proximity to the mixing circuit. Multiple functions (mixing and heat exchange) are combined in one device, improving thermal management efficiency while avoiding the complexity of separate coupled systems.
Solution Approach 2:
The heat exchange circuit is arranged in a different spatial dimension (transverse direction) relative to the mixing circuit flow direction. This dimensional arrangement allows close thermal coupling without interfering with the mixing flow paths, achieving efficient heat exchange while maintaining structural clarity.
3Object-affected harmful factors
If traditional cooling methods with coolant circulation around the device are used, then thermal management is achieved, but cooling effectiveness is insufficient and thermal runaway may occur
Solution Approach 1:
The heat exchange circuit is nested within or interleaved with the mixing circuit structure, with heat exchange channels positioned between mixing channels. This nested arrangement allows the coolant to be in close proximity to the reacting fluids, dramatically improving cooling effectiveness and preventing thermal runaway compared to external cooling methods.
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 configuration ensures intimate mixing of chemical reagents while enabling optimal heat exchange, preventing thermal runaway and allowing for industrial-scale production of complex reactor structures with improved mechanical properties.
Implementation Method 1
a second circuit called the 'heat exchange circuit' arranged as close as possible to the mixing circuit... ensuring an exchange effective thermal with the outside
Implementation Method 2
The production method provides for implementing a welding-diffusion step, preferably by hot isostatic pressing
Data Source
Figure 1~2
Figure 3~4
Figure 5A
AI summary
The invention relates to a device forming a chemical reactor comprising a first circuit for forming a chemical reactor, said first circuit comprising a plurality of channels (10) in which at least two chemical substances circulate so as to react with each other, said channels (10) having a three-dimensional structure comprising elbows and forks imposing changes of direction on the fluid, and a second heat exchanging circuit comprising a plurality of channels (36) in which a heat transfer fluid circulates as closely as possible to the channels (10) wherein the reaction is taking place.