Stacked Plate Reactor Cassettes for Faster Catalyst Testing
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Solution Overview
Problem
Existing high-throughput research methods for studying chemical processes are inefficient and complex, particularly in catalyst development and process optimization, requiring improved apparatuses and software for faster and more accurate testing.
Innovation Solution
An apparatus with a stacked plate reactor system, featuring modular, quick-change clamping devices, and standardized insertion cassettes for leak-tight and thermally isolated reactors, allowing for simultaneous or correlated chemical studies on multiple functional elements with varied process parameters, including reactive and nonreactive devices for different chemical processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional reactor systems are used for catalyst testing, then the apparatus can perform chemical processes, but the setup is complex and time-consuming requiring manual component assembly
Solution Approach 1:
The reactor system is divided into modular components: a reactor body, interchangeable catalyst cassettes, and standardized connection elements. Each cassette is a self-contained unit that can be independently assembled and replaced, eliminating the need for complex manual assembly of individual reactor components while enabling parallel testing of multiple catalysts simultaneously
Solution Approach 2:
The reactor body is designed with universal connection interfaces and standardized mounting structures that accommodate various cassette types. The same reactor body can perform multiple functions by simply changing the cassette insertions, allowing a single apparatus to test different catalysts, supports, and process conditions without requiring separate specialized equipment for each test
2Productivity
If multiple catalysts are tested simultaneously in separate apparatuses, then the number of tests increases, but the time required for setup and assembly increases
Solution Approach 1:
Multiple individual reactor units are merged into a single integrated multi-cassette reactor system. Several catalyst cassettes are positioned side-by-side within one reactor body, sharing common fluid distribution systems, heating/cooling channels, and connection interfaces. This allows simultaneous testing of multiple catalysts in parallel while using a single apparatus, eliminating the setup time required to assemble and connect multiple separate reactor systems
Solution Approach 2:
The catalyst cassettes are pre-assembled with their respective catalyst materials, supports, and sealing elements before insertion into the reactor body. This preliminary assembly is performed outside the reactor system, allowing for quality control and optimization of each catalyst configuration independently, while the final integration into the reactor body is a simple quick-change operation that minimizes setup time
3Adaptability or versatility
If reactor components are made customizable for different tests, then the adaptability increases, but the complexity of assembly and configuration increases
Solution Approach 1:
The cassettes are designed with standardized interfaces and mounting structures that provide uniform attachment characteristics throughout the reactor body. Local variations in catalyst type, support material, or geometric configuration are achieved by changing the cassette insertions rather than modifying the overall reactor structure. This maintains ease of operation through consistent assembly procedures while enabling high adaptability through cassette variety
Solution Approach 2:
Instead of creating custom reactor configurations from scratch for each test, the system uses standardized cassette templates and modular components that can be replicated and reused. The same reactor body and connection system serve all tests, with only the cassette inserts varying. This copying approach maintains operational simplicity while providing extensive adaptability through the availability of different standardized cassette designs
4Adaptability or versatility
If manual assembly of reactor components is performed, then the configuration can be customized, but the time required for assembly increases
Solution Approach 1:
The cassettes are designed as self-contained units with integrated sealing elements, mounting features, and alignment structures that enable straightforward insertion into the reactor body without requiring complex assembly procedures. The standardized interfaces allow the cassette to essentially assemble itself through simple mechanical engagement, eliminating the need for time-consuming manual adjustment and alignment operations while maintaining configuration flexibility
Data Source
AI summary
The invention relates to a device, stacked plate reactor and to a method for investigating chemical processes to be carried out simultaneously or almost at the same time on a large number of functional element variations of the process parameters.