Manifold designs, and flow control in multichannel microchannel devices

• US 9,475,026 B2
• Filed: 07/22/2013
• Issued: 10/25/2016
• Est. Priority Date: 10/27/2003
• Status: Expired due to Fees

• Current Assignee: Velocys Incorporated (Velocys PLC)
• Original Assignee: Velocys Incorporated (Velocys PLC)
• Inventors: Qui (deceased), Dongming, Fitzgerald, Sean P., Tonkovich, Anna Lee, Arora, Ravi, Yuschak, Thomas D., Silva, Laura J., Rogers, Wm. Allen, Jarosch, Kai, Schmidt, Matthew B.
• Primary Examiner(s): Nagpaul, Jyoti
• Application Number:
  US13/947,978
• Publication Number:
  US 20140332081A1
• Time in Patent Office: 1,191 Days
• US Class Current: 1/1
• 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 2219/00781 Aspects relating to microreactors
• CPC Class Codes: B01J 2219/00783 Laminate assemblies, i.e. the reactor comprising a stack of plates
• CPC Class Codes: B01J 2219/0086 Dimensions of the flow channels
• CPC Class Codes: B01J 2219/00891 Feeding or evacuation
• CPC Class Codes: B01J 2219/00995 Mathematical modeling
• CPC Class Codes: C01B 2203/0233 the reforming step being a steam reforming step
• CPC Class Codes: C01B 2203/0811 by combustion of fuel
• CPC Class Codes: C01B 2203/0822 the fuel containing hydrogen
• CPC Class Codes: C01B 3/384 the catalyst being continuously externally heated
• CPC Class Codes: F15D 1/001 Flow of fluid from conduits such as pipes, sleeves, tubes, with equal distribution of fluid flow over the evacuation surface
• CPC Class Codes: F15D 1/04 Arrangements of guide vanes in pipe elbows or duct bends; Construction of pipe conduit elements for elbows with respect to flow, e.g. for reducing losses of flow
• CPC Class Codes: F28F 2260/02 having microchannels
• CPC Class Codes: F28F 3/08 Elements constructed for building-up into stacks, e.g. capable of being taken apart for cleaning
• CPC Class Codes: Y02P 20/10 Process efficiency
• CPC Class Codes: Y10T 137/0318 Processes
• CPC Class Codes: Y10T 137/85938 Non-valved flow dividers
• CPC Class Codes: Y10T 436/2575 Volumetric liquid transfer

Abstract

Novel manifolds and methods of flow through manifolds are described. Apparatus and techniques are described in which flow from a relatively large volume header is equally distributed to process channels. Methods of making laminated, microchannel devices are also described.

Claims

1. Microchannel apparatus, comprising:

a first channel extending in a first direction;

a second channel extending in a second direction; and

a third channel extending in the second direction;

a fourth channel extending in the second direction; and

a fifth channel extending in the second direction;

wherein the first and second directions are substantially coplanar;

wherein the second and third channels are adjacent and parallel;

wherein the first channel is not parallel to either the second or third channels;

wherein the first channel is connected to the second channel and the third channels via a first gate;

wherein the third channel is positioned farther in the first direction than the second channel;

wherein the third channel comprises a microchannel;

wherein the second channel comprises a microchannel;

wherein the second channel has an opening with a first cross-sectional area and the third channel has an opening with a second cross-sectional area;

wherein the first gate has a cross-sectional area that is smaller than the sum of first and second cross-sectional areas and the wall cross-sectional area between them;

wherein the fourth and fifth channels are adjacent and parallel;

wherein the first channel is connected to the fourth channel and the fifth channels via a second gate;

wherein the fourth and fifth channels are positioned farther in the first direction than the third channel;

wherein the fourth channel comprises a microchannel;

wherein the fifth channel comprises a microchannel;

wherein the fourth channel has an opening with a third cross-sectional area and the fifth channel has an opening with a fourth cross-sectional area;

wherein the second gate has a cross-sectional area that is smaller than the sum of third and fourth cross-sectional areas and the wall cross-sectional area between them; and

wherein the cross-sectional area of the first gate differs from that of the cross-sectional area of the second gate.

2. The microchannel apparatus of claim 1 wherein the first gate has a cross-sectional area between 2-98% of the combined cross-sectional areas of the connecting microchannels served by the first gate.

3. The microchannel apparatus of claim 1 wherein the apparatus is a laminate and the first gate comprises a sheet with a cross-bar.

4. A method of distributing flow from a manifold through a connecting channel matrix, comprising:

passing a fluid through a manifold inlet and into a manifold having the following characteristics;

the height of the manifold (h_m2m) is 2 mm or less;

the length of the manifold (L_m2m) is 7.5 cm or greater;

the length of an optional straightening channel portion (L₂) divided by L_m2m is less than 6;

passing the fluid into the manifold with a momentum (Mo) of at least 0.05

maintaining the DPR₂ ratio at 2 or greater or maintaining a DPR₃ ratio of 0.9 or less; and

distributing the fluid from the manifold into at least 2 channels which are connected to the manifold, with a quality index factor as a function of connecting channel areas of

Q(Ra)=0.0008135Ra⁶−

0.03114Ra⁵+0.4519Ra⁴−

3.12Ra³+11.22Ra²−

23.9Ra+39.09.

5. The method of claim 4 wherein R_a is equal to or less than 12.

6. The method of claim 5 wherein the fluid flow rate through the manifold is maintained such that the quantity {*0.058+0.0023(ln Re)²(D)*/L_M2M} is less than 0.01, where Re is Reynolds number.

7. The method of claim 5 wherein FA is less than 0.01.

8. The method of claim 4 wherein R_a is equal to or less than 3.

9. A method of distributing flow from a manifold through a connecting channel matrix, comprising:

passing a fluid through a manifold inlet and into a manifold such that the fluid passes through a first portion of a manifold in a first flow regime and passes through a second portion of a manifold in a second flow regime

wherein the manifold manifold has the following characteristics;

the height of the manifold (h_m2m) is 2 mm or less;

the length of an optional straightening channel portion (L₂) divided by L_m2m is less than 6;

maintaining the DPR₂ ratio at 2 or greater or maintaining a DPR₃ ratio of 0.9 or less; and

distributing the fluid from the manifold into at least 2 channels, which are connected to the manifold, with a quality index factor as a function of connecting channel areas of

Q(Ra)=0.0008135Ra⁶−

0.03114Ra⁵+0.4519Ra⁴−

3.12Ra³+11.22Ra²−

23.9Ra+39.09.

10. The method of claim 9 wherein the first flow regime is turbulent and second flow regime is transitional.

11. The method of claim 10 wherein R_a is equal to or less than 12.

12. The method of claim 11 further comprising passing the fluid through a macromanifold that is connected to the manifold inlet.