MICROREACTOR SYSTEMS AND METHODS

• US 20160129417A1
• Filed: 11/10/2015
• Published: 05/12/2016
• Est. Priority Date: 11/11/2014
• Status: Active Grant

• Current Assignee: HC Starck Solutions Coldwater LLC
• Original Assignee: Marc Abouaf, Patrick Hogan, Paul R. Aimone
• Inventors: AIMONE, Paul R., ABOUAF, Marc, HOGAN, Patrick
• Granted Patent: US 10,105,671 B2
• Time in Patent Office: 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 19/02 Apparatus characterised by being constructed of material selected for its chemically-resistant properties
• CPC Class Codes: B01J 19/2415 Tubular reactors
• CPC Class Codes: B01J 2219/00092 Tubes
• CPC Class Codes: B01J 2219/00822 Metal
• CPC Class Codes: B01J 2219/00837 comprising coatings other than catalytically active coatings
• CPC Class Codes: B01J 2219/00873 Heat exchange
• CPC Class Codes: B01J 2219/0236 Metal based
• CPC Class Codes: B01J 2219/0277 Metal based
• CPC Class Codes: B22D 19/0072 for making objects with integrated channels
• CPC Class Codes: B22F 10/14 by jetting of binder onto a bed of metal powder
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/38 to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
• CPC Class Codes: B22F 10/43 characterised by material
• CPC Class Codes: B22F 3/12 Both compacting and sintering by forging B22F3/17
• CPC Class Codes: B22F 5/10 of articles with cavities or holes, not otherwise provided for in the preceding subgroups
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

In various embodiments, a microreactor features a corrosion-resistant microchannel network encased within a thermally conductive matrix material that may define therewithin one or more hollow heat-exchange conduits.

Claims

1. A microreactor comprising:

a network of hollow microchannel conduits formed of a corrosion-resistant material; and

surrounding and in contact with the microchannel conduits, a matrix comprising a matrix material having a thermal conductivity larger than a thermal conductivity of the corrosion-resistant material.

2. The microreactor of claim 1, further comprising one or more hollow heat-exchange channels each (i) defined by the matrix material, (ii) proximate one or more microchannel conduits, and (iii) not intersecting any of the microchannel conduits.

3. The microreactor of claim 2, wherein a diameter of at least one heat-exchange channel is larger than a diameter of at least one microchannel conduit.

4. The microreactor of claim 1, wherein the corrosion-resistant material comprises at least one of niobium, molybdenum, tantalum, tungsten, rhenium, titanium, zirconium, glass, or stainless steel.

5. The microreactor of claim 1, wherein the matrix material comprises at least one of aluminum, gold, brass, silver, or copper.

6. The microreactor of claim 1, wherein a portion of the matrix proximate the microchannel conduits comprises a mixed and/or graded composition comprising the corrosion-resistant material and the matrix material.

7. The microreactor of claim 1, wherein the network of microchannel conduits comprises (i) two or more input conduits converging to a single reaction zone, and (ii) an output conduit leading away from the reaction zone.

8. A method of fabricating a microreactor, the method comprising:

forming a network of hollow microchannel conduits from a corrosion-resistant material; and

thereafter and/or thereduring, surrounding the network of microchannel conduits with a matrix material having a thermal conductivity larger than a thermal conductivity of the corrosion-resistant material.

9. The method of claim 8, further comprising defining a plurality of hollow heat-exchange conduits within the matrix material, the heat-exchange conduits not intersecting the microchannel conduits.

10. The method of claim 8, wherein the network of microchannel conduits is formed by an additive manufacturing technique.

11. The method of claim 10, wherein the additive manufacturing technique comprises three-dimensional printing.

12. The method of claim 10, wherein the matrix material is formed around the microchannel conduits via the additive manufacturing technique.

13. The method of claim 8, wherein the matrix material is disposed around the microchannel conduits by at least one of casting or powder pressing.

14. The method of claim 8, wherein the corrosion-resistant material comprises at least one of niobium, molybdenum, tantalum, tungsten, rhenium, titanium, zirconium, glass, or stainless steel.

15. The method of claim 8, wherein the matrix material comprises at least one of aluminum, gold, brass, silver, or copper.

16. A method of fabricating a microreactor, the method comprising:

shaping and joining metal sheet into one or more microchannel conduits, the metal sheet comprising a corrosion-resistant material;

fabricating one or more microreactor parts each configured to interface with one or more of the microchannel conduits via an additive manufacturing technique utilizing a feedstock comprising the corrosion-resistant material;

joining the one or more microchannel conduits to the one or more microreactor parts, thereby forming a microchannel network of the microreactor; and

thereafter, encasing the microchannel network within a matrix material having a thermal conductivity larger than a thermal conductivity of the corrosion-resistant material.

17. The method of claim 16, further comprising, during or after the encasing of the microchannel network within the matrix material, defining within the matrix material one or more hollow heat-exchange conduits, the one or more heat-exchange conduits not intersecting the microchannel network.

18. The method of claim 16, wherein the microchannel network is encased within the matrix material via an additive manufacturing technique.

19. The method of claim 16, wherein the microchannel network is encased within the matrix material via at least one of casting or powder pressing.

20. The method of claim 16, wherein the corrosion-resistant material comprises at least one of niobium, molybdenum, tantalum, tungsten, rhenium, titanium, zirconium, glass, or stainless steel.

21. The method of claim 16, wherein the matrix material comprises at least one of aluminum, gold, brass, silver, or copper.