Stacked Plate Reactor-Exchanger with Variable Cross-Section Channels
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Solution Overview
Problem
Existing reactor-heat exchangers face challenges in effectively controlling temperature during highly exothermic or endothermic catalytic reactions, which affects conversion rate, selectivity, and catalyst deactivation, while also compromising compactness and increasing manufacturing costs.
Innovation Solution
A reactor-heat exchanger module with a stack configuration featuring reactant circuit channels of increasing section, where adjacent channels flow in opposite directions, allowing for improved temperature control and maximizing conversion rates without sacrificing compactness, and incorporating a modular design for flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional reactor-heat exchangers are used for highly exothermic or endothermic catalytic reactions, then thermal control is difficult to achieve, but increasing the heat transfer surface area would improve temperature control
Solution Approach 1:
The patent implements nested channels where reactant channels and heat transfer fluid channels are interpenetrating and intertwined within the same reactor volume. This nested configuration maximizes the heat transfer surface area without increasing the external reactor volume, allowing effective thermal control of highly exothermic or endothermic reactions within a compact footprint.
2Temperature
If the reactant channels have constant cross-section, then the reactor design is simpler, but temperature control at the hottest point is insufficient
Solution Approach 1:
The patent employs reactant channels with variable cross-sectional area that changes along the flow direction, creating different local geometries optimized for different reaction zones. The channel cross-section is designed to be smaller at the inlet where temperature control is critical and larger at the outlet, providing localized thermal management where it is most needed while maintaining manageable overall complexity.
3Temperature
If adjacent reactant channels flow in the same direction, then the flow distribution is simpler, but thermal control efficiency is reduced
Solution Approach 1:
The patent implements counter-flow configuration where adjacent reactant channels flow in opposite directions. This inversion of the conventional co-flow arrangement creates more efficient thermal control by maximizing the temperature gradient between channels, allowing heat to be transferred more effectively from hot channels to cooler adjacent channels throughout the reactor length.
4Temperature
If more heat transfer fluid channels are added, then temperature control improves, but the reactor becomes less compact
Solution Approach 1:
The patent merges the reactant channels and heat transfer fluid channels into a single integrated structure where both functions coexist within the same volume. The interpenetrating channel configurations allow heat transfer fluid channels to be positioned within the spaces between reactant channels, effectively combining multiple functions in a compact arrangement rather than requiring separate dedicated spaces for each function.
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 effectively controls the maximum temperature at the hottest point, maintains high conversion rates, and enhances operational flexibility by reducing unnecessary material and thermal inertia, while allowing for modular assembly and efficient catalyst distribution.
Implementation Method 1
The second fluid circuit, usually called the utility or heat transfer circuit, serves to thermally control the chemical reaction, either by supplying the heat necessary for the reaction or, conversely, by removing the heat released by it.
Implementation Method 2
a small quantity of co-reactants is simultaneously injected into the inlet of a first fluid circuit... the resulting chemical product is recovered at the outlet of this first circuit
Implementation Method 3
The main application targeted is the realization of catalytic reactors, and in particular catalytic reactors using solid catalysts and dedicated to strongly exothermic or endothermic reactions.
Implementation Method 4
the reactions are either highly exothermic or highly endothermic... by removing the heat released by it
Implementation Method 5
the reactions are either highly exothermic or highly endothermic... by supplying the heat necessary for the reaction
Data Source
Figure 1~3
Figure 4~6C
Figure 7A~8
AI summary
The invention relates to a heat exchanger reactor module having at least two fluid circuits, comprising a stack of grooved plate sheets assembled together by hot isostatic compression, defining heat transfer channels and reactant channels. According to the invention, the reactant circuit channels each have an increasing flow cross-section over at least part of their length, and in that two adjacent reactant circuit channels (21.1, 21.2) are arranged end-to-end such that when traversing a channel (21.1) in one direction along the longitudinal axis (X), its geometric cross-section increases, while when traversing the adjacent channel (21.2) in the same direction along the longitudinal axis (X), its geometric cross-section decreases.