Scalable continuous production system

• US 7,435,392 B2
• Filed: 06/06/2003
• Issued: 10/14/2008
• Est. Priority Date: 02/03/2000
• Status: Expired due to Fees

• Current Assignee: Ehrfeld Mikrotechnik BTS GmbH (Bayer AG)
• Original Assignee: Acclavis, LLC
• Inventors: Schwalbe, Thomas, Autze, Volker, Poelderl, Klaus, Oberbeck, Sebastian
• Primary Examiner(s): Warden; Jill
• Assistant Examiner(s): Handy; Dwayne K
• Application Number:
  US10/456,162
• Publication Number:
  US 20030223909A1
• Time in Patent Office: 1,957 Days
• Field of Search: 422/99, 422/101, 422/102, 422/104, 422/129, 422/130, 422/131, 422/134
• US Class Current: 422/130
• CPC Class Codes: B01F 25/422 between stacked plates, e.g. grooved or perforated plates
• CPC Class Codes: B01F 33/30 Micromixers
• CPC Class Codes: B01F 33/3012 Interdigital streams, e.g. lamellae
• CPC Class Codes: B01F 33/3017 Mixing chamber
• CPC Class Codes: B01F 33/3039 with mixing achieved by diffusion between layers
• CPC Class Codes: B01F 33/304 the mixing being performed in a mixing chamber where the products are brought into contact
• CPC Class Codes: B01F 33/81 Combinations of similar mixers, e.g. with rotary stirring devices in two or more receptacles
• CPC Class Codes: B01F 33/813 mixing simultaneously in two or more mixing receptacles
• CPC Class Codes: B01F 35/90 Heating or cooling systems
• CPC Class Codes: B01J 19/0033 Optimalisation processes, i.e. processes with adaptive control systems adaptive control systems per se G05B13/00
• CPC Class Codes: B01J 19/0093 Microreactors, e.g. miniaturised or microfabricated reactors laboratory containers with capillary fluid transport in microfabricated channels or chambers B01L3/5027
• CPC Class Codes: B01J 19/249 Plate-type reactors
• CPC Class Codes: B01J 2219/00783 Laminate assemblies, i.e. the reactor comprising a stack of plates
• CPC Class Codes: B01J 2219/00822 Metal
• CPC Class Codes: B01J 2219/00831 Glass
• CPC Class Codes: B01J 2219/00833 Plastic
• CPC Class Codes: B01J 2219/00869 Microreactors placed in parallel, on the same or on different supports
• CPC Class Codes: B01J 2219/00873 Heat exchange
• CPC Class Codes: B01J 2219/00889 Mixing micromixers B01F33/30
• CPC Class Codes: B01J 2219/00891 Feeding or evacuation
• CPC Class Codes: B01J 2219/00961 : Temperature
• CPC Class Codes: B01J 2219/00986 : Microprocessor
• CPC Class Codes: B01J 2219/0099 : Cleaning
• CPC Class Codes: B01J 2219/2453 : Plates arranged in parallel
• CPC Class Codes: B01J 2219/2456 : Geometry of the plates
• CPC Class Codes: B01J 2219/246 : Perforated plates
• CPC Class Codes: B01J 2219/2462 : the reactants being in indirect heat exchange with a non reacting heat exchange medium
• CPC Class Codes: B01J 2219/2464 : Independent temperature control in various sections of the reactor
• CPC Class Codes: B01J 2219/247 : Feeding means for the reactants
• CPC Class Codes: B01J 2219/2485 : Metals or alloys
• CPC Class Codes: B01J 2219/2486 : Steel
• CPC Class Codes: B01J 2219/2487 : Ceramics
• CPC Class Codes: B01J 2219/2488 : Glass
• CPC Class Codes: B01J 2219/249 : Plastics
• CPC Class Codes: B01J 2219/2493 : Means for assembling plates together, e.g. sealing means, screws, bolts
• CPC Class Codes: B01J 2219/2495 : the plates being assembled interchangeably or in a disposable way
• CPC Class Codes: B01J 2219/2496 : Means for assembling modules together, e.g. casings, holders, fluidic connectors
• CPC Class Codes: B01J 2219/2497 : Size aspects, i.e. concrete sizes are being mentioned in the classified document
• CPC Class Codes: F28D 9/0075 : the plates having openings therein for circulation of the heat-exchange medium from one conduit to another
• CPC Class Codes: F28D 9/0093 : Multi-circuit heat-exchangers, e.g. integrating different heat exchange sections in the same unit or heat-exchangers for more than two fluids
• CPC Class Codes: F28F 2260/02 : having microchannels
• CPC Class Codes: F28F 9/26 : Arrangements for connecting different sections of heat-exchange elements, e.g. of radiators connecting different sections in water heaters F24H9/14 , connecting headers with inlet or outlet fittings F28F9/0246

Abstract

A parallel chemical production system producing a desired product by operating a plurality of reactors in parallel. The fluidic properties of each of the reactors are identical to the properties of a test reactor employed to determine conditions for producing the product, to facilitate scaling up production. In one embodiment, the production system is configured such that at least one reactor is always offline for cleaning, servicing, and use as a backup. If sensors detect less than optimal conditions in any reactor, the reactor is taken offline and serviced, while a previously designated backup reactor is placed online to maintain continuous production. Another aspect involves arranging the reactors in a concentric configuration to facilitate equal fluid distribution.

Claims

1. An automated continuous processing parallel chemical production system for automatically producing a desired chemical product by combining at least two reactants, the chemical production system comprising:

(a) a plurality of chemical reactors, each chemical reactor being configured to produce a quantity of the desired chemical product, each chemical reactor comprising at least;

a first reactant inlet, a second reactant inlet, a reaction volume coupled in fluid communication with the first reactant inlet and the second reactant inlet, and a product outlet coupled in fluid communication with the reaction volume;

(b) a reactant feed apparatus including;

(i) a first reactant feed assembly configured to be placed in fluid communication with a supply of a first reactant, and to selectively couple said first reactant inlet of each chemical reactor in fluid communication with the supply of the first reactant, so that each first reactant inlet of the plurality of chemical reactors is coupled in parallel, with the supply of the first reactant; and

(ii) a second reactant feed assembly configured to be placed in fluid communication with a supply of a second reactant, and to selectively couple said second reactant inlet of each chemical reactor in fluid communication with the supply of the second reactant, so that each second reactant inlet of the plurality of chemical reactors is coupled in parallel, with the supply of the second reactant;

(c) a product collection assembly configured to be placed in fluid communication with a product receiver, and to selectively couple said product outlet of each chemical reactor in fluid communication with the product receiver; and

(d) a system controller controllably coupled with said first reactant feed assembly, said second reactant feed assembly, and said product collection assembly, the system controller monitoring and controlling production of the desired chemical product by said plurality of chemical reactors, and designating at least one of said plurality of chemical reactors as a backup reactor, such that the system controller causes;

(i) said first reactant feed assembly to isolate said first reactant inlet of the backup reactor from the supply of the first reactant, while coupling said first reactant inlet of each other chemical reactor in parallel fluid communication with the supply of the first reactant, such that while the system is automatically producing the desired chemical product, the first reactant inlet of each reactor not designated as a backup reactor is coupled in fluid communication with the first reactant feed assembly, such that a first reactant fluid is simultaneously supplied to each reactor not designated as a backup reactor;

(ii) said second reactant feed assembly to isolate said second reactant inlet of the backup reactor from the supply of the second reactant, while coupling said second reactant inlet of each other chemical reactor in parallel fluid communication with the supply of the second reactant, such that while the system is automatically producing the desired chemical product, the second reactant inlet of each reactor not designated as a backup reactor is coupled in fluid communication with the second reactant feed assembly, such that a second reactant fluid is simultaneously supplied to each reactor not designated as a backup reactor; and

(iii) said product collection assembly to isolate said product outlet of the backup reactor from said product receiver, while coupling the product outlet of each other chemical reactor in fluid communication with the product receiver.

2. The automated continuous processing parallel chemical production system of claim 1, wherein each chemical reactor comprises a microreactor.

3. The automated continuous processing parallel chemical production system of claim 1, wherein each chemical reactor is configured to provide substantially identical processing conditions.

4. The automated continuous processing parallel chemical production system of claim 1, wherein each chemical reactor is substantially identical to a test reactor employed to determine preferred processing conditions for producing the desired chemical product, before the automated parallel chemical production system is employed to produce the desired chemical product.

5. The automated continuous processing parallel chemical production system of claim 1, wherein the system controller designates a different one of the plurality of chemical reactors as the backup reactor after a predefined period, the chemical reactor previously designated as the backup reactor being then coupled in fluid communication with the supply of the first reactant, the supply of the second reactant, and the product receiver, while the chemical reactor that is newly designated as the backup reactor is isolated from the supply of the first reactant, the supply of the second reactant, and the product receiver, thereby making the newly designated backup reactor available for maintenance operations, to facilitate continuous production of the desired product over extended periods of time.

6. The automated continuous processing parallel chemical production system of claim 1, wherein the product collection assembly includes a sensor for each chemical reactor, each sensor being disposed between the product outlet of the chemical reactor and the product receiver, so that an indication of the quality of the chemical product from the chemical reactor is provided to the system controller.

7. The automated continuous processing parallel chemical production system of claim 6, wherein the system controller is programmed to designate a different one of the plurality of chemical reactors as the backup reactor when one of said sensors indicates that the quality of the chemical product produced by its corresponding chemical reactor deviates from a predetermined standard, the chemical reactor that was previously designated as the backup reactor being then coupled with the supply of the first reactant, the supply of the second reactant, and the product receiver, while the newly designated backup reactor is isolated from the supply of the first reactant, the supply of the second reactant, and the product receiver, thereby making the newly designated backup reactor available for maintenance operations, to facilitate continuous production of the desired product over extended periods of time.

8. The automated continuous processing parallel chemical production system of claim 1, wherein:

(a) said first reactant feed assembly and said second reactant feed assembly are each respectively configured to be selectively coupled in fluid communication with a first solvent supply and a second solvent supply, such that for each chemical reactor;

(i) said first reactant feed assembly can selectively couple said first reactant inlet in fluid communication with one of the first reactant supply and the first solvent supply; and

(ii) said second reactant feed assembly can selectively couple said second reactant inlet in fluid communication with one of the second reactant supply and the second solvent supply; and

(b) said product collection assembly is configured to be selectively coupled in fluid communication with a waste receiver, such that for each chemical reactor, said product collection assembly can selectively couple said product outlet in fluid communication with one of the product receiver and the waste receiver, thereby enabling the backup reactor to be flushed with solvent.

9. The automated continuous processing parallel chemical production system of claim 1, further comprising a common heat exchange assembly coupled in fluid communication with each chemical reactor and a heat transfer media supply, the common heat exchange assembly providing substantially equivalent thermal conditions in each chemical reactor.

10. The automated continuous processing parallel chemical production system of claim 9, wherein the plurality of chemical reactors are arranged in a generally concentric configuration, and said common heat exchange assembly comprises a first ring-shaped fluid manifold disposed outwardly of the plurality of chemical reactors, and a second ring-shaped fluid manifold disposed inwardly of the plurality of chemical reactors, each chemical reactor being coupled in fluid communication with the first and second ring-shaped fluid manifolds.

11. The automated continuous processing parallel chemical production system of claim 10, wherein the first fluid line provides each chemical reactor with fresh heat transfer media, and the second fluid line recovers spent heat transfer media from each chemical reactor.

12. The automated continuous processing parallel chemical production system of claim 1, wherein the plurality of chemical reactors are arranged in a generally concentric configuration.

13. The automated continuous processing parallel chemical production system of claim 12, wherein:

(a) the first reactant feed assembly comprises;

(i) a first reactant distributor configured to couple in fluid communication with the supply of the first reactant; and

(ii) a plurality of first reactant fluid lines configured to selectively couple said first reactant distributor to each first reactant inlet of said plurality of chemical reactors, each first reactant fluid line being configured to provide a substantially equivalent flow rate of the first reactant fluid; and

(b) the second reactant feed assembly comprises;

(i) a second reactant distributor configured to couple in fluid communication with the supply of the second reactant; and

(ii) a plurality of second reactant fluid lines configured to selectively couple said second reactant distributor to each second reactant inlet of said plurality of chemical reactors, each second reactant fluid line being configured to provide a substantially equivalent flow rate of the second reactant fluid.

14. The automated continuous processing parallel chemical production system of claim 13, wherein:

(a) each first reactant fluid line comprises a valve configured to selectively couple the first reactant inlet of each reactor in fluid communication with one of the supply of the first reactant and the first solvent supply, each valve being controllably coupled with the system controller; and

(b) each second reactant fluid line comprises a valve configured to selectively couple the second reactant inlet of each reactor in fluid communication with one of the supply of the second reactant and the second solvent supply, each valve being controllably coupled with the system controller.

15. The automated continuous processing parallel chemical production system of claim 12, wherein said product collection assembly comprises:

(a) a product collector configured to couple in fluid communication with the product receiver; and

(b) a plurality of product fluid lines configured to selectively couple said product collector to each product outlet of said plurality of chemical reactors, each product fluid line being configured to provide a substantially equivalent flow rate.

16. The automated continuous processing parallel chemical production system of claim 15, wherein each product fluid line comprises a valve configured to selectively couple the product outlet of each reactor in fluid communication with one of the product receiver and the waste receiver, each valve being controllably coupled with the system controller.

17. The automated continuous processing parallel chemical production system of claim 1, further comprising a product heat exchange assembly configured to thermally condition a product discharged from each reactor outlet.

18. The automated continuous processing parallel chemical production system of claim 1, wherein the product collection assembly comprises a thermal conditioning structure configured to thermally condition a product discharged from each reactor outlet.

19. The automated continuous processing parallel chemical production system of claim 1, wherein each chemical reactor comprises a plurality of simple plates stacked together in layers, each reactor including a first inlet pathway coupled to said first reactant inlet, a second inlet pathway coupled to said second reactant inlet, each inlet pathway merging within the reactor to form at least one reaction chamber in which at least two chemical reactants react to generate a chemical product, at least one outlet pathway coupling said at least one reaction chamber in fluid communication with said product outlet, and wherein each first reactant inlet, first reactant pathway, second reactant inlet, second reactant pathway, reaction chamber, and product outlet comprises an opening through at least one simple plate aligned with at least a portion of an opening through an adjacent simple plate.

20. The automated continuous processing parallel chemical production system of claim 1, wherein each chemical reactor comprises a plurality of simple plates, stacked in layers, each simple plate having at least one opening that extends therethrough, an opening in each simple plate overlapping at least one other opening in an adjacent simple plate, said simple plates, when thus stacked in layers, defining:

(a) a fluid path for the first and second reactants;

(b) a fluid path for the desired chemical product;

(c) a fluid path for a heat transfer medium;

(d) a heat exchanger coupled in fluid communication with the fluid path for the heat transfer medium; and

(e) means for manipulating a flow of fluid in said stacked plate reactor to achieve a desired result.

21. The automated continuous processing parallel chemical production system of claim 1, wherein each chemical reactor comprises a plurality of simple plates, stacked in layers, each simple plate having at least one opening that extends therethrough, an opening in each simple plate overlapping at least one other opening in an adjacent simple plate, thereby forming:

(a) a fluid path for the first and second reactants;

(b) a processing volume in fluid communication with each fluid path for the first and second reactants;

(c) a fluid path for the desired chemical product in fluid communication with the processing volume;

(d) a fluid path for a heat transfer medium;

(e) a heat exchanger in fluid communication with the fluid path for the heat transfer medium and disposed so as to moderate a temperature of at least one of the first reactant, the second reactant, the processing volume, and the fluid path for the desired chemical product; and

(f) means for enhancing at least one of;

(i) a quantity of the desired chemical product that is produced by said stacked plate reactor per unit time; and

(ii) a quality of the desired chemical product that is produced by said stacked plate reactor.

22. The automated continuous processing parallel chemical production system of claim 1, wherein the plurality of reactors and the reactant feed apparatus are configured as a first stage, and further comprising a plurality of additional chemical reactors, the plurality of additional chemical reactors and the product collection assembly being configured as a second stage, such that:

(a) a number of the additional chemical reactors in the second stage is equal to a number of the plurality of reactors in the first stage;

(b) each additional chemical reactor in the second stage includes at least an inlet and a second stage product outlet;

(c) each product outlet of each chemical reactor in the first stage is coupled to the inlet of one of the additional chemical reactors in the second stage, such that each additional chemical reactor in the second stage is coupled with only one chemical reactor in the first stage; and

(d) each second stage product outlet of each additional chemical reactor in the second stage is coupled to the product collection assembly, to selectively couple the product outlet of each additional chemical reactor in the second stage in fluid communication with the product receiver; and

wherein instead of isolating the product outlet of the backup reactor in the first stage from the product receiver, while coupling the product outlet of each other chemical reactor in the first stage in fluid communication with the product receiver, the system controller causes the product collection assembly to isolate the second stage product outlet of the additional chemical reactor in the second stage whose inlet is coupled to the outlet of the backup reactor in the first stage, from the product receiver, while coupling the second stage product outlet of each other additional chemical reactor in the second stage in fluid communication with the product receiver.

23. The automated continuous processing parallel chemical production system of claim 1, wherein the plurality of reactors and the reactant feed apparatus are configured as a first stage, and further comprising:

(a) a plurality of additional chemical reactors, such that;

(i) the plurality of additional chemical reactors and the product collection assembly are configured as a second stage;

(ii) a number of the additional chemical reactors in the second stage is equal to a number of the plurality of reactors in the first stage; and

(iii) each additional chemical reactor in the second stage includes at least an inlet and a second stage product outlet, each second stage product outlet being coupled to the product collection assembly, to selectively couple the product outlet of each additional chemical reactor in the second stage in fluid communication with the product receiver;

(b) a valve system disposed in fluid communication with each outlet of the plurality of chemical reactors in the first stage, and each inlet of the plurality of additional chemical reactors in the second stage, the valve system being controllably connected to the system controller, the valve system selectively coupling the product outlet of a selected chemical reactor in the first stage to the inlet of a selected additional chemical reactor in the second stage under the control of the system controller; and

wherein instead of isolating the product outlet of the backup reactor in the first stage from the product receiver, while coupling the product outlet of each other chemical reactor in the first stage in fluid communication with the product receiver, the system controller causes the product collection assembly to isolate the second stage product outlet of the additional chemical reactor in the second stage whose inlet is selectively coupled to the outlet of the backup reactor in the first stage from the product receiver.

24. The automated continuous processing parallel chemical production system of claim 1, wherein the plurality of reactors, the reactant feed apparatus and the product collection assembly are configured as a first stage, and further comprising a second stage, the second stage including:

(a) a plurality of additional chemical reactors, each additional chemical reactor in the second stage including at least;

an inlet, and a second stage product outlet; and

(b) a second stage feed assembly configured to be placed in fluid communication with the product receiver, and to selectively couple the inlet of each additional chemical reactor in fluid communication with the product receiver, so that each additional chemical reactor is coupled in parallel with the product receiver;

the second stage feed assembly being controllably connected to the system controller;

wherein the system controller designates at least one of the additional reactors in the second stage as a backup reactor, and causes the second stage feed assembly to isolate the inlet of each additional chemical reactor in the second stage designated as the backup reactor from the product receiver.

25. The automated continuous processing parallel chemical production system of claim 1, wherein:

(a) the plurality of reactors and the reactant feed apparatus are configured as a first stage, and further comprising a plurality of additional chemical reactors, the plurality of additional chemical reactors being configured as at least one additional stage, such that;

(i) a number of the additional chemical reactors in each additional stage is equal to a number of the plurality of reactors in the first stage, and each additional chemical reactor includes at least an inlet and a product outlet;

(ii) the inlet of each additional chemical reactor in each additional stage is coupled in fluid communication with one of the product outlet of a corresponding chemical reactor in the first stage and the product outlet of a corresponding chemical reactor in a preceding additional stage; and

(iii) the outlet of each additional chemical reactor in each additional stage is coupled in fluid communication with one of the inlet of a corresponding chemical reactor in a subsequent additional stage, and the product collection assembly; and

(b) the system controller designates a corresponding number of additional chemical reactors in each additional stage as backup reactors, ensures the product outlet of each additional chemical reactor designated as backup reactor is isolated from the product receiver, and ensures the product outlet of each additional chemical not designated as a backup reactor is coupled in fluid communication with the product receiver.

26. A concentrically parallel chemical production system for producing a desired chemical product by combining at least two reactants, the chemical production system comprising:

(a) a first stage including;

(i) a plurality of chemical reactors, each chemical reactor being configured to produce a quantity of the desired chemical product, each chemical reactor of the plurality of chemical reactors having at least;

a first reactant inlet, a second reactant inlet, a reaction volume coupled in fluid communication with the first reactant inlet and the second reactant inlet, and a product outlet, the plurality of chemical reactors being arranged in a generally concentric configuration, such that each reactor comprises an inner end and an outer end, each inner end being disposed relatively closer to a center of a circle defined by the plurality of chemical reactors than each outer end, the first reactant inlet and the second reactant inlet for each chemical reactor being disposed proximate the inner end of that reactor;

(ii) a reactant feed apparatus including;

(1) a first reactant feed assembly configured to be placed in fluid communication with a supply of a first reactant, and to couple said first reactant inlet of each chemical reactor in parallel fluid communication with the supply of the first reactant; and

(2) a second reactant feed assembly configured to be placed in fluid communication with a supply of a second reactant, and to couple said second reactant inlet of each chemical reactor in parallel fluid communication with the supply of the second reactant; and

(iii) a product collection assembly configured to be placed in fluid communication with a product receiver, and to couple said product outlet of each chemical reactor in fluid communication with the product receiver; and

(b) a second stage including;

(i) a plurality of additional chemical reactors, each additional chemical reactor in the second stage including at least an inlet and a second stage product outlet; and

(ii) a second stage feed assembly configured to be placed in fluid communication with the product receiver, and to selectively couple the inlet of each additional chemical reactor in fluid communication with the product receiver, so that each additional chemical reactor is coupled in parallel with the product receiver, to enable the product collected from the first stage to be introduced as a reactant in the second stage.

27. The concentrically parallel chemical production system of claim 26, wherein:

(a) the first reactant feed assembly comprises;

(i) a first reactant distributor configured to couple in fluid communication with the supply of the first reactant; and

(ii) a plurality of first reactant fluid lines configured to selectively couple said first reactant distributor to each first reactant inlet of said plurality of chemical reactors, each first reactant fluid line being configured to provide a substantially equivalent flow rate, each first reactant fluid line including a first reactant fluid line valve configured to selectively couple the first reactant inlet of each reactor in fluid communication with one of the supply of the first reactant and a first solvent supply;

(b) the second reactant feed assembly comprises;

(i) a second reactant distributor configured to couple in fluid communication with a supply of a second reactant; and

(ii) a plurality of second reactant fluid lines configured to selectively couple said second reactant distributor to each second reactant inlet of said plurality of chemical reactors, each second reactant fluid line being configured to provide a substantially equivalent flow rate, each second reactant fluid line including a second reactant fluid line valve configured to selectively couple the second reactant inlet of each reactor in fluid communication with one of the supply of the second reactant and a second solvent supply; and

(c) the product collection assembly comprises;

(i) a product collector configured to couple in fluid communication with the product receiver; and

(ii) a plurality of product fluid lines configured to selectively couple said product collector to each product outlet of said plurality of chemical reactors, each product fluid line being configured to provide a substantially equivalent flow rate, each product fluid line including a product fluid line valve configured to selectively couple the product outlet of each reactor in fluid communication with one of the product receiver and a waste receiver, whereby each chemical reactor can selectively be isolated from the other chemical reactors and flushed with solvent.

28. The concentrically parallel chemical production system of claim 26, further comprising a common heat exchange assembly coupled in fluid communication with each chemical reactor in at least one of the first and second stages, and a heat transfer media supply, the common heat exchange assembly providing substantially equivalent thermal conditions in each chemical reactor in at least one of the first and second stages.

29. The concentrically parallel chemical production system of claim 26, wherein said common heat exchange assembly comprises a first fluid line and a second fluid line, said first and second fluid lines being configured as concentric rings, and wherein the plurality of chemical reactors in the first stage are disposed between said concentric rings.

30. The concentrically parallel chemical production system of claim 26, wherein each chemical reactor comprises a microreactor.

31. The concentrically parallel chemical production system of claim 26, wherein each chemical reactor in at least one of the first and second stages is configured to provide substantially identical processing conditions.

32. The concentrically parallel chemical production system of claim 26, further comprising a system controller controllably coupled with said first reactant feed assembly, said second reactant feed assembly, and said product collection assembly, the system controller being programmed to monitor and control production of the desired chemical product by said plurality of chemical reactors, including designating one of said plurality of chemical reactors in the first stage as a backup reactor, such that the system controller causes:

(a) said first reactant feed assembly to isolate said first reactant inlet of the backup reactor from the supply of the first reactant, while coupling said first reactant inlet of each other chemical reactor in fluid communication with the supply of the first reactant;

(b) said second reactant feed assembly to isolate said second reactant inlet of the backup reactor from the supply of the second reactant, while coupling said second reactant inlet of each other chemical reactor in fluid communication with the supply of the second reactant; and

(c) said product collection assembly to isolate said product outlet of the backup reactor from said product receiver, while coupling the product outlet of each other chemical reactor in fluid communication with the product receiver.

33. The concentrically parallel chemical production system of claim 32, wherein the system controller is programmed to designate a different one of the plurality of chemical reactors in the first stage as the backup reactor after a predefined period, a previously designated backup reactor being coupled in fluid communication with the supply of the first reactant, the supply of the second reactant, and the product receiver, while a newly designated backup reactor is isolated from the supply of the first reactant, the supply of the second reactant, and the product receiver, thereby making the newly designated backup reactor available for maintenance operations, to facilitate continuous production of the desired product over extended periods of time.

34. The concentrically parallel chemical production system of claim 32, wherein:

(a) the product collection assembly includes a sensor for each chemical reactor in the first stage, each sensor being disposed between the product outlet of the chemical reactor and the product receiver, each sensor being coupled to the system controller, so that an indication of the quality of the chemical product from the chemical reactor is provided to the system controller; and

(b) the system controller is programmed to designate a different one of the plurality of chemical reactors as the backup reactor when one of said sensors indicates that the quality of the chemical product produced by its corresponding chemical reactor deviates substantially from a predetermined standard, a previously designated backup reactor being coupled with the supply of the first reactant, the supply of the second reactant, and the product receiver, while a newly designated backup reactor is isolated from the supply of the first reactant, the supply of the second reactant, and the product receiver, thereby making the newly designated backup reactor available for maintenance operations, to facilitate continuous production of the desired product over extended periods of time.

35. The concentrically parallel chemical production system of claim 26, further comprising a product heat exchange assembly configured to thermally condition a product discharged from each reactor outlet.

36. The concentrically parallel chemical production system of claim 26, wherein the product collection assembly comprises a thermal conditioning structure configured to thermally condition a product discharged from each reactor outlet.

37. A concentrically parallel chemical production system for producing a desired chemical product by combining at least two reactants, the chemical production system comprising:

(a) a first stage including;

(i) a plurality of chemical reactors, each chemical reactor being configured to produce a quantity of the desired chemical product, each chemical reactor of the plurality of chemical reactors having at least;

a first reactant inlet, a second reactant inlet, a reaction volume coupled in fluid communication with the first reactant inlet and the second reactant inlet, and a product outlet, the plurality of chemical reactors being arranged in a generally concentric configuration, such that each reactor comprises an inner end and an outer end, each inner end being disposed relatively closer to a center of a circle defined by the plurality of chemical reactors than each outer end, the first reactant inlet and the second reactant inlet for each chemical reactor being disposed proximate the inner end of that reactor;

(ii) a first reactant feed assembly configured to be placed in fluid communication with a supply of a first reactant, and to couple said first reactant inlet of each chemical reactor in parallel fluid communication with the supply of the first reactant; and

(iii) a second reactant feed assembly configured to be placed in fluid communication with a supply of a second reactant, and to couple said second reactant inlet of each chemical reactor in parallel fluid communication with the supply of the second reactant;

(b) a final product collection assembly configured to couple in fluid communication with a product receiver; and

(c) at least one additional stage, each additional stage including a plurality of chemical reactors arranged in a generally concentric configuration, such that;

(i) a number of the plurality of chemical reactors in each additional stage is equal to a number of the plurality of reactors in the first stage, and each chemical reactor in each additional stage includes at least an inlet and a product outlet;

(ii) the inlet of each chemical reactor in each additional stage is coupled in fluid communication with one of the product outlet of a corresponding chemical reactor in the first stage or the product outlet of a corresponding chemical reactor in a preceding additional stage; and

(iii) the outlet of each chemical reactor in each additional stage is coupled in fluid communication with one of the inlet of a corresponding chemical reactor in a subsequent additional stage, and the final product collection assembly.

38. The concentrically parallel chemical production system of claim 37, wherein at least one of the first stage and the at least one additional stage includes a product collection assembly configured to couple the product outlet of each chemical reactor in that stage, such that the product produced in that stage is provided to a subsequent stage as a single product stream.

39. The concentrically parallel chemical production system of claim 37, wherein the product outlet of each chemical reactor in the first stage is coupled to the inlet of a different chemical reactor in one of the at least one additional stages.

40. The concentrically parallel chemical production system of claim 37, further comprising a valve system disposed in fluid communication with each outlet of the plurality of chemical reactors in the first stage, and each inlet of the plurality of chemical reactors in a subsequent additional stage, the valve system enabling the selective coupling of the product outlet of each chemical reactor in the first stage to the inlet of a different selected chemical reactor in the subsequent additional stage.

41. The concentrically parallel chemical production system of claim 37, further comprising a system controller controllably connected to the first reactant feed assembly, the second reactant feed assembly, and the product collection assembly, the system controller being configured to automate operation of the concentrically parallel chemical production system.

42. The concentrically parallel chemical production system of claim 41, further comprising a plurality of sensors, each sensor being logically coupled with the system controller, each sensor being configured to provide an indication of a quality of a product produced in at least one of each chemical reactor in the first stage and each chemical reactor in each additional stage, the system controller being configured to designate each chemical reactor producing a product having a quality that is less than a predefined quality as a backup reactor.

43. An automated continuous processing parallel chemical production system for automatically producing a desired chemical product by combining at least two reactants, the chemical production system comprising:

(a) a first stage including;

(i) a plurality of chemical reactors, each chemical reactor being configured to produce a quantity of the desired chemical product, each chemical reactor of the plurality of chemical reactors having at least;

a first reactant inlet, a second reactant inlet, and a product outlet;

(ii) a first reactant feed assembly configured to be placed in fluid communication with a supply of a first reactant, and to couple the first reactant inlet of each chemical reactor in parallel fluid communication with the supply of the first reactant; and

(iii) a second reactant feed assembly configured to be placed in fluid communication with a supply of a second reactant, and to couple the second reactant inlet of each chemical reactor in parallel fluid communication with the supply of the second reactant;

(b) a product collection assembly configured to couple in fluid communication with a product receiver;

(c) at least one additional stage, each additional stage including a plurality of additional chemical reactors, such that;

(i) a number of the additional chemical reactors in each additional stage is equal to a number of the plurality of reactors in the first stage, and each additional chemical reactor includes at least an inlet and a product outlet;

(ii) the inlet of each additional chemical reactor in each additional stage is coupled in fluid communication with one of the product outlet of a corresponding chemical reactor in the first stage or the product outlet of a corresponding chemical reactor in a preceding additional stage; and

(iii) the outlet of each additional chemical reactor in each additional stage is coupled in fluid communication with one of the inlet of a corresponding chemical reactor in a subsequent additional stage, or the product collection assembly, the product collection assembly being further configured to selectively couple each product outlet of each additional chemical reactor in a final additional stage in fluid communication with a product receiver; and

(d) a system controller controllably coupled with the first reactant feed assembly, the second reactant feed assembly, and the product collection assembly, the system controller monitoring and controlling production of the desired chemical product by the plurality of chemical reactors, and designating at least one of the plurality of chemical reactors in the first stage as a backup reactor, and at least one of the plurality of additional chemical reactors in each additional stage as a backup reactor, such that the system controller causes;

(i) the first reactant feed assembly to isolate the first reactant inlet of the backup reactor from the supply of the first reactant, while continuing to couple the first reactant inlet of each other chemical reactor in parallel fluid communication with the supply of the first reactant;

(ii) the second reactant feed assembly to isolate the second reactant inlet of the backup reactor from the supply of the second reactant, while continuing to couple the second reactant inlet of each other chemical reactor in parallel fluid communication with the supply of the second reactant; and

(iii) the product collection assembly to isolate the product outlet of each additional chemical reactor in the final additional stage that is designated as a backup reactor from a product receiver, while continuing to couple the product outlet of each other additional chemical reactor in the final additional stage in fluid communication with a product receiver.

44. An automated continuous processing parallel chemical production system for automatically producing a desired chemical product by combining at least two reactants, the chemical production system comprising:

(a) a first stage including;

(i) a plurality of chemical reactors, each chemical reactor being configured to produce a quantity of the desired chemical product, each chemical reactor of the plurality of chemical reactors having at least;

a first reactant inlet, a second reactant inlet, and a product outlet;

(ii) a first reactant feed assembly configured to be placed in fluid communication with a supply of a first reactant, and to couple the first reactant inlet of each chemical reactor in parallel fluid communication with the supply of the first reactant; and

(iii) a second reactant feed assembly configured to be placed in fluid communication with a supply of a second reactant, and to couple the second reactant inlet of each chemical reactor in parallel fluid communication with the supply of the second reactant;

(b) a second stage including a plurality of additional chemical reactors, such that;

(i) there are at least as many additional chemical reactors in the second stage as there are chemical reactors in the first stage; and

(ii) each additional chemical reactor in the second stage includes at least;

an inlet and a second stage product outlet, each additional chemical reactor inlet being configured to receive a product produced in the first stage and to use the product as a reactant to produce a second stage product;

(c) a product collection assembly configured to couple the second stage product outlet of each chemical reactor in the second stage in fluid communication with a product receiver; and

(d) a system controller controllably coupled with the first reactant feed assembly, the second reactant feed assembly, and the product collection assembly, the system controller monitoring and controlling production of the desired chemical product by the plurality of chemical reactors, and designating at least one of the plurality of chemical reactors in the first stage as a backup reactor, and at least one of the plurality of additional chemical reactors in the second stage as a backup reactor, such that the system controller causes;

(i) the first reactant feed assembly to isolate the first reactant inlet of the backup reactor from the supply of the first reactant, while continuing to couple the first reactant inlet of each other chemical reactor in parallel fluid communication with the supply of the first reactant;

(ii) the second reactant feed assembly to isolate the second reactant inlet of the backup reactor from the supply of the second reactant, while continuing to couple the second reactant inlet of each other chemical reactor in parallel fluid communication with the supply of the second reactant; and

(iii) the product collection assembly to isolate the second stage product outlet of the second stage backup reactor from the product receiver, while continuing to couple the second stage product outlet of each other additional chemical reactor in the second stage in fluid communication with the product receiver.

45. The automated continuous processing parallel chemical production system of claim 44, wherein:

(a) the first stage further includes a first stage product collection assembly configured to couple the product outlet of each chemical reactor in the first stage in fluid communication with the second stage, the first stage product collection assembly including a product fluid channel and a waste fluid channel, the first stage product collection assembly being controllably coupled to the system controller, such that the system controller causes the first stage product collection assembly to couple the product outlet of the first stage backup reactor to the waste fluid channel, while coupling the product outlet of each other chemical reactor in the first stage in fluid communication with the product fluid channel, such that the product produced in the first stage is provided to the second stage as a single product stream; and

(b) the second stage further includes a second stage reactant feed assembly configured to be placed in fluid communication with the first stage product collection assembly, and to couple the inlet of each additional chemical reactor in the second stage in parallel fluid communication with the first stage product collection assembly, the second stage reactant feed assembly being controllably coupled to the system controller, such that the system controller causes the second stage reactant feed assembly to isolate the inlet of the second stage backup reactor from the product fluid channel of the first stage product collection assembly, while coupling the inlet of each other additional chemical reactor in the second stage in fluid communication with the product fluid channel of the first stage product collection assembly.

46. The automated continuous processing parallel chemical production system of claim 44, wherein the product outlet of each chemical reactor in the first stage is coupled to the inlet of a different additional chemical reactor in the second stage.

47. The automated continuous processing parallel chemical production system of claim 44, further comprising a valve system disposed in fluid communication with each outlet of the plurality of chemical reactors in the first stage, and each inlet of the plurality of additional chemical reactors in the second stage, the valve system being controllably coupled to the system controller, such that the system controller causes:

(a) the product outlet of the designated backup reactor in the first stage to be coupled in fluid communication with the inlet of the designated backup reactor in the second stage; and

(b) the product outlet of each chemical reactor in the first stage not designated as the backup reactor in the first stage to be coupled in fluid communication with the inlet of a selected different one of the additional chemical reactors in the second stage, where the different one of the additional chemical reactors is not designated as the backup reactor in the second stage.

48. The automated continuous processing parallel chemical production system of claim 44, wherein the plurality of reactors in the first stage are arranged in a substantially concentric orientation, to enhance the distribution of reactants to the plurality of chemical reactors.

49. The automated continuous processing parallel chemical production system of claim 44, further comprising a plurality of sensors, each sensor being logically coupled with the system controller, each sensor being configured to provide an indication of the quality of a product produced in at least one of each chemical reactor in the first stage and each additional chemical reactor in the second stage, the system controller being configured to designate each reactor producing a product having a quality that is less than a predefined quality as a backup reactor.

50. A concentrically parallel chemical production system for producing a desired chemical product by combining at least two reactants, the chemical production system comprising:

(a) a first stage including;

(i) a plurality of chemical reactors, each chemical reactor being configured to produce a quantity of the desired chemical product, each chemical reactor of the plurality of chemical reactors having at least;

a first reactant inlet, a second reactant inlet, a reaction volume coupled in fluid communication with the first reactant inlet and the second reactant inlet, and a product outlet, the plurality of chemical reactors being arranged in a generally concentric configuration, such that each reactor comprises an inner end and an outer end, each inner end being disposed relatively closer to a center of a circle defined by the plurality of chemical reactors than each outer end, the first reactant inlet and the second reactant inlet for each chemical reactor being disposed proximate the inner end of that reactor; and

(ii) a reactant feed apparatus including;

(1) a first reactant feed assembly configured to be placed in fluid communication with a supply of a first reactant, and to couple said first reactant inlet of each chemical reactor in parallel fluid communication with the supply of the first reactant; and

(2) a second reactant feed assembly configured to be placed in fluid communication with a supply of a second reactant, and to couple said second reactant inlet of each chemical reactor in parallel fluid communication with the supply of the second reactant; and

(b) a second stage including a plurality of additional chemical reactors and a product collection assembly, the plurality of additional chemical reactors and the product collection assembly being configured such that;

(i) a number of the additional chemical reactors in the second stage is equal to a number of the plurality of reactors in the first stage;

(ii) each additional chemical reactor in the second stage includes at least;

an inlet, and a second stage product outlet;

(iii) the product collection assembly is configured to be placed in fluid communication with a product receiver, and to couple the second stage product outlet of each chemical reactor in the second stage in fluid communication with the product receiver; and

(iv) each product outlet of each chemical reactor in the first stage is coupled to the inlet of a different one of the additional chemical reactors in the second stage, such that each additional chemical reactor in the second stage is coupled with only one chemical reactor in the first stage.

51. A concentrically parallel chemical production system for producing a desired chemical product by combining at least two reactants, the chemical production system comprising:

(a) a first stage including;

(i) a plurality of chemical reactors, each chemical reactor being configured to produce a quantity of the desired chemical product, each chemical reactor of the plurality of chemical reactors having at least;

a first reactant inlet, a second reactant inlet, a reaction volume coupled in fluid communication with the first reactant inlet and the second reactant inlet, and a product outlet, the plurality of chemical reactors being arranged in a generally concentric configuration, such that each reactor comprises an inner end and an outer end, each inner end being disposed relatively closer to a center of a circle defined by the plurality of chemical reactors than each outer end, the first reactant inlet and the second reactant inlet for each chemical reactor being disposed proximate the inner end of that reactor; and

(ii) a reactant feed apparatus including;

(1) a first reactant feed assembly configured to be placed in fluid communication with a supply of a first reactant, and to couple said first reactant inlet of each chemical reactor in parallel fluid communication with the supply of the first reactant; and

(2) a second reactant feed assembly configured to be placed in fluid communication with a supply of a second reactant, and to couple said second reactant inlet of each chemical reactor in parallel fluid communication with the supply of the second reactant;

(b) a second stage including a plurality of additional chemical reactors and a product collection assembly, the plurality of additional chemical reactors and the product collection assembly being configured such that;

(i) a number of the additional chemical reactors in the second stage is equal to a number of the plurality of reactors in the first stage;

(ii) each additional chemical reactor in the second stage includes at least;

an inlet, and a second stage product outlet;

(iii) the product collection assembly is configured to be placed in fluid communication with a product receiver, and to couple the second stage product outlet of each chemical reactor in the second stage in fluid communication with the product receiver; and

(iv) each product outlet of each chemical reactor in the first stage is coupled to the inlet of a different one of the additional chemical reactors in the second stage, such that each additional chemical reactor in the second stage is coupled with only one chemical reactor in the first stage; and

(c) a valve system disposed in fluid communication with the outlet of each of the plurality of chemical reactors in the first stage, and the inlet of each of the plurality of additional chemical reactors in the second stage, the valve system enabling the selective coupling of the product outlet of each chemical reactor in the first stage to the inlet of a selected additional chemical reactor in the second stage.