Flow distribution channels to control flow in process channels

• US 9,752,831 B2
• Filed: 10/27/2014
• Issued: 09/05/2017
• Est. Priority Date: 04/25/2006
• Status: Active Grant

• Current Assignee: Velocys Incorporated (Velocys PLC)
• Original Assignee: Velocys Incorporated (Velocys PLC)
• Inventors: Tonkovich, Anna Lee, Arora, Ravi, Kilanowski, David
• Primary Examiner(s): CHAUDRY, ATIF H
• Application Number:
  US14/523,952
• Publication Number:
  US 20150068608A1
• Time in Patent Office: 1,044 Days
• CPC Class Codes: B01F 23/41 Emulsifying
• CPC Class Codes: B01F 25/3142 the conduit having a plurality of openings in the axial direction or in the circumferential direction
• CPC Class Codes: B01F 25/433 Mixing tubes wherein the shape of the tube influences the mixing, e.g. mixing tubes with varying cross-section or provided with inwardly extending profiles
• CPC Class Codes: B01F 25/4331 Mixers with bended, curved, coiled, wounded mixing tubes or comprising elements for bending the flow
• CPC Class Codes: B01F 25/4338 Mixers with a succession of converging-diverging cross-sections, i.e. undulating cross-section
• CPC Class Codes: B01F 33/30 Micromixers
• CPC Class Codes: B01F 33/3017 Mixing chamber
• CPC Class Codes: B01F 33/305 using mixing means not otherwise provided for B01F25/00, B01F27/00, B01F29/00, B01F31/00, B01F33/301 - B01F33/3045, B01F33/40 and B01F33/45 take precedence
• 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 2219/00783 Laminate assemblies, i.e. the reactor comprising a stack of plates
• CPC Class Codes: B01J 2219/00835 Comprising catalytically active material
• CPC Class Codes: B01J 2219/0086 Dimensions of the flow channels
• 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
• CPC Class Codes: B01J 2219/00891 Feeding or evacuation
• CPC Class Codes: F28D 1/0316 Assemblies of conduits in parallel F28D1/0325, F28D1/035 take precedence
• CPC Class Codes: F28D 1/0341 with U-flow or serpentine-flow inside the conduits
• CPC Class Codes: F28F 1/022 with multiple channels
• CPC Class Codes: F28F 2260/02 having microchannels
• CPC Class Codes: F28F 3/04 : the means being integral with the element
• CPC Class Codes: F28F 9/0275 : with multiple branch pipes
• CPC Class Codes: Y10T 137/0318 : Processes
• CPC Class Codes: Y10T 137/0329 : Mixing of plural fluids of diverse characteristics or conditions
• CPC Class Codes: Y10T 137/6579 : Circulating fluid in heat exchange relationship
• CPC Class Codes: Y10T 137/85938 : Non-valved flow dividers
• CPC Class Codes: Y10T 137/87571 : Multiple inlet with single outlet
• CPC Class Codes: Y10T 137/87652 : With means to promote mixing or combining of plural fluids

Abstract

The invention describes features that can be used to control flow to an array of microchannels. The invention also describes methods in which a process stream is distributed to plural microchannels.

Claims

1. A process of combining fluids, comprising:

passing a first fluid through a process channel, wherein the process channel is a channel in an array of parallel process channels in a layer;

passing a second fluid through a FDC and into the process channel where the first and second fluids combine, where the FDC comprises a series of turns, comprising at least four turns that are 90°

or less, or comprising at least two turns that are greater than 90°

;

wherein the first and second fluids are different; and

wherein the FDC comprises at least two turns that have different angles.

2. The process of claim 1 wherein the mass flow rate of the first fluid into the process channel is 5% or less than the flow rate of the second fluid in the process channel.

3. The process of claim 1 where the process channels are straight and wherein flow in the process channel is non-Newtonian.

4. A process of combining fluids, comprising:

passing a first fluid through a process channel, wherein the process channel is a channel in an array of parallel process channels in a layer;

passing a second fluid through a FDC and into the process channel where the first and second fluids combine, where the FDC comprises a series of turns, comprising at least four turns that are 90°

or less, or comprising at least two turns that are greater than 90°

;

wherein the first and second fluids are different; and

wherein the second fluid flows through channels in a second layer that is adjacent to the layer comprising the array of parallel process channels.

5. The method of claim 4 wherein the number of process channels is 5 to 100 times greater than the number of channels through which the second fluid flows in the second layer.

6. The method of claim 4 wherein the FDC has a height in the range of 0.05 mm to 10 mm.

7. The method of claim 4 wherein the channels in the second layer through which the second fluid flows are perpendicular to the array of parallel process channels.

8. The method of claim 7 wherein the channels in the second layer comprise a second array of parallel channels wherein each channel is connected through a FDC to a manifold in the second layer.

9. A process of combining fluids, comprising:

passing a first fluid through a process channel, wherein the process channel is a channel in an array of parallel process channels in a layer;

passing a second fluid through a FDC and into the process channel where the first and second fluids combine, where the FDC comprises a series of turns, comprising at least four turns that are 90°

or less, or comprising at least two turns that are greater than 90°

;

wherein the first and second fluids are different; and

wherein an emulsion is formed by passing the first fluid through the array of parallel process channels that have channel walls with orifices and the second fluid, which is immiscible with the first fluid, passes through the orifices into the first fluid to form an emulsion.