Rotating Thin Film Reactor for Uniform Organic Synthesis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional reactors face challenges in achieving uniform reaction conditions, particularly in chemical reactions involving organic compounds, due to nonuniformity in concentration and temperature, leading to reduced yield and increased risks associated with hazardous materials and environmental pollution.
Innovation Solution
A method involving a reaction in a forced thin film fluid formed between processing surfaces that rotate relative to each other, ensuring high uniformity and selectivity, and allowing for continuous processing with reduced viscosity impact and minimized risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional batch type or flow type reactors are used, then chemical reactions can be performed, but nonuniformity in concentration and temperature distribution occurs leading to reduced reaction selectivity and yield
Solution Approach 1:
The reaction system is segmented into multiple thin film flow paths between opposing processing surfaces. Each thin film region acts as an independent reaction zone with uniform heat and mass transfer characteristics, eliminating the nonuniformity problems of conventional reactors while maintaining high productivity through continuous flow processing.
Solution Approach 2:
The invention transitions from conventional three-dimensional bulk reaction zones to two-dimensional thin film flow paths. This dimensional reduction enables superior heat and mass transfer uniformity across the reaction field, as the thin film geometry ensures equitable distribution of reactants and uniform temperature profiles, directly addressing the nonuniformity issue.
2Manufacturing precision
If stirring devices are added to achieve uniform reaction conditions, then mixing speed increases, but power consumption continuously rises especially for high viscosity fluids
Solution Approach 1:
The invention extracts the mixing function from mechanical stirring devices and achieves it through the hydrodynamic flow pattern inherent in the thin film system. The continuous flow between opposing surfaces naturally ensures uniform mixing without requiring additional mechanical energy input, eliminating the trade-off between mixing quality and power consumption.
Solution Approach 2:
The invention replaces the mechanical stirring system with a fluid dynamic system where continuous flow through thin film paths achieves mixing. This substitution eliminates the need for mechanical stirrers and their associated power consumption, particularly benefiting high viscosity fluids where mechanical stirring becomes prohibitively energy-intensive.
3Productivity
If rapid heating is applied to reduce reaction time, then productivity increases, but excessive heat energy is required due to large temperature gradients
Solution Approach 1:
The transition to two-dimensional thin film geometry dramatically improves heat transfer efficiency and uniformity. The reduced dimensionality eliminates large temperature gradients that occur in bulk reactors, enabling rapid heating with minimal energy input since heat penetrates uniformly across the thin film thickness without creating significant thermal stratification.
Solution Approach 2:
The invention changes the geometric parameter of the reaction zone from bulk three-dimensional volume to thin film two-dimensional surface, characterized by small gap dimensions. This parameter change fundamentally improves the heat transfer surface-to-volume ratio, allowing rapid and uniform heating with reduced energy consumption and eliminating the need for excessive heating power.
4Productivity
If reactor capacity is increased to meet production demands, then productivity improves, but nonuniformity in reaction field worsens
Solution Approach 1:
The invention segments the reaction system into multiple parallel thin film flow paths between opposing processing surfaces. This segmentation allows the system to scale in capacity by increasing the number or width of thin film channels rather than increasing bulk volume, thereby maintaining uniform reaction conditions even at large production scales.
Solution Approach 2:
By transitioning to two-dimensional thin film geometry, the system achieves scale-up capability without sacrificing uniformity. The thin film configuration ensures that even when processing large volumes through multiple parallel paths, each individual reaction zone maintains uniform heat and mass transfer, preventing the nonuniformity that plagues scaled-up conventional reactors.
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 approach enables high reaction selectivity, efficient energy use, and scalable production while maintaining uniformity, reducing the risks associated with organic reactions and improving productivity.
Implementation Method 1
a forced thin film fluid which is formed between processing surfaces (1, 2) arranged to be opposite to each other so as to be able to approach to and separate from each other, at least one of which rotates relative to the other
Data Source
Figure 1(A)~1(D)
Figure 2(A)~2(D)
Figure 3(A)~3(F)
AI summary
Disclosed herein are a reaction method and a production method of an organic compound which are capable of achieving high reaction selectivity according to the purpose and a high production rate of a target substance. The methods include at least two fluids, wherein at least one kind of the fluids is a fluid containing at least one organic compound and at least one kind of the fluids other than the above fluid is a fluid containing at least one reactant in the form of a liquid or solution, and the respective fluids join together in a thin film fluid formed between processing surfaces arranged to be opposite to each other so as to be able to approach to and separate from each other, at least one of which rotates relative to the other, whereby an organic reaction is performed in the thin film fluid.