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WO2025032231A1 - Commande de l'alimentation en liquide de refroidissement dans des microréacteurs - Google Patents

Commande de l'alimentation en liquide de refroidissement dans des microréacteurs Download PDF

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Publication number
WO2025032231A1
WO2025032231A1 PCT/EP2024/072608 EP2024072608W WO2025032231A1 WO 2025032231 A1 WO2025032231 A1 WO 2025032231A1 EP 2024072608 W EP2024072608 W EP 2024072608W WO 2025032231 A1 WO2025032231 A1 WO 2025032231A1
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WIPO (PCT)
Prior art keywords
coolant
flow
individual
reactor
supply line
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PCT/EP2024/072608
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German (de)
English (en)
Inventor
Sebastian FICHTNER
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Ineratec GmbH
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Ineratec GmbH
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Publication of WO2025032231A1 publication Critical patent/WO2025032231A1/fr
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0093—Microreactors, e.g. miniaturised or microfabricated reactors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00051—Controlling the temperature
    • B01J2219/00054—Controlling or regulating the heat exchange system
    • B01J2219/00056—Controlling or regulating the heat exchange system involving measured parameters
    • B01J2219/00069—Flow rate measurement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00781—Aspects relating to microreactors
    • B01J2219/00783—Laminate assemblies, i.e. the reactor comprising a stack of plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00781—Aspects relating to microreactors
    • B01J2219/00819—Materials of construction
    • B01J2219/00822—Metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00781—Aspects relating to microreactors
    • B01J2219/00819—Materials of construction
    • B01J2219/00844—Comprising porous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00781—Aspects relating to microreactors
    • B01J2219/00873—Heat exchange
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00781—Aspects relating to microreactors
    • B01J2219/0095—Control aspects
    • B01J2219/00984—Residence time

Definitions

  • the present invention relates to microreactors comprising a regulating device for the coolant supply, in which at least one series resistor based on a microporous structure is inserted into the central coolant supply line and/or individual coolant channels, and/or at least one synchronous flow divider is arranged between the central coolant supply line and the supply lines to the individual coolant channels; methods for cooling exothermic reactions taking place in a microreactor and for regulating the reactor operation and/or the coolant supply with corresponding regulation of the coolant supply, as well as corresponding uses.
  • solid catalysts can be introduced as layers or as particle fillings.
  • Such reactors are usually used for fast and high-energy reactions in order to ensure an efficient heat inflow or outflow with the help of a layer structure, i.e. through alternating levels with flow of reaction medium and heat transfer medium, and thus to operate the reaction as close to a set temperature as possible.
  • the parallel structures are filled with catalytically active material, a particle size distribution that is as narrowly distributed as possible is advantageous so that the local porosity in the entire particle cluster is as identical as possible during filling and an even distribution of the mass flow across the parallel structures is possible F. Dadgar et al., Chemical Engineering Science, Volume 177, Pages 110-121. If the pressure loss in the particle cluster is sufficiently high, external flow conditions become almost irrelevant for the even distribution.
  • US 8,492,164 B2 proposes using individual supply channels running in a plane transverse to the structures and creating narrow openings of different sizes by overlapping different plates when constructing the structured reactor, so that the total resistance from the common inlet to a common outlet of all structures is identical due to different flow resistances along the supply channels and the total volume flow is distributed uniformly across the entire structure.
  • US 9,752,831 B2 in a similar arrangement of transverse supply channels to the individual channel structures, a curved channel segment with a significantly smaller channel cross-section is also proposed in front of the channel structures, which creates a specifically high pressure loss and thus creates an uniform distribution.
  • a similar approach for distribution within a structured reactor is proposed in WO 2006/107206 A2 using a planar series resistor consisting of various sub-segments in which vertical and horizontal slots alternate, each of which covers the entire inlet cross-section of the structured reactor.
  • US 2013/0165536 Al describes the combination of microchannel (coolant) and minichannel (reaction), whereby partial evaporation over a length of more than 25 cm is possible due to the high speed in the microchannel of >10 cm/s.
  • the channel of the coolant is 50% horizontally aligned.
  • curved channels and parallel sub-distributions for cooling that are transverse to the reaction flow are proposed in order to achieve uniform evaporation regardless of the direction of gravity.
  • US 6,149,882 discloses a parallel flow reactor for screening heterogeneous catalysts in which the inflow is controlled using flow restrictors such as capillaries or adjustable valves to obtain substantially the same flow in each of the reaction channels.
  • WO 97/32208 and DE 198 09 477 also describe parallel flow reactors with uniform flow through each of the reaction channels.
  • WO 99/41005 and DE 198 06 848 also disclose parallel flow reactor configurations.
  • WO 00/51720 describes a parallel flow reactor design that addresses various technical challenges including the challenge of flow distribution for screening catalysts in parallel in very large numbers.
  • DE 601 08 482 T2 also describes the challenges of parallel testing of catalysts in mini reactors with flow restrictors including different flow settings for different parallel reactors.
  • the object of the present invention was therefore to overcome the disadvantages of the prior art described above and to provide measures, devices and methods which no longer have these problems or at least only have them to a considerably lesser extent.
  • the aim was to find a microreactor configuration which avoids the disadvantages of the state of the art and improves the known reactors and/or reactor configurations; in particular, an improved, uniform cooling should be achieved, even when the cooling media are operated close to their boiling point.
  • the dimensions of such microreactors are preferably, but not limited to, the following:
  • the flow area for coolant is 50 mm to 1000 mm long, the reaction passage perpendicular to it is between 100 mm and 2000 mm.
  • the thickness of the wall between these passages can be between 0.2 mm and 3 mm.
  • the channel heights can be 0.2 mm to 2 mm.
  • the channel widths are variable. Examples of inventive Microreactors that can be used (and improved in their cooling configuration) are known, for example, from WO 2017/013003A1.
  • the front of the reactor is understood to be the side from which the reaction medium/fluid flows into the reactor
  • the rear of the reactor is understood to be the side from which the reaction medium/fluid exits the reactor.
  • a feed line or a pipe is mentioned in the context of the present invention, this is to be understood in particular as a device that enables fluids (reaction fluids, coolants) to be transported therein.
  • hoses and the like can also be included in a broader sense and viewed as a usable alternative (provided they can be used in the respective specific case).
  • the reference system used in the present invention is an observer standing upright on the ground in front of the object under discussion.
  • ambient temperature means a temperature of 20°C. Temperatures are in degrees Celsius (°C), unless otherwise stated.
  • the present invention firstly relates to a microreactor in which coolant is passed through the reactor in cross-flow to the reaction medium.
  • Crossflow means that the cooling medium is passed through the reactor essentially at a 90° angle to the reaction medium (of course in separate layers/channels). It is not important to maintain the 90° exactly, so flow angles of 45° are also quite suitable, nor does it matter that the coolant channels in the levels with flow of heat transfer medium (and the reaction channels in the levels with flow of reaction medium) run strictly straight. It is also possible to let the coolant channels (just like the reaction channels) run meanderingly or jaggedly or similarly. In principle, diversions upwards or downwards or sub-distributions of the coolant channels within the reactor are also possible.
  • the coolant channels and the reaction channels are arranged approximately 90° to each other (in particular between 90° and 80° to each other) and the channels each run in a straight line.
  • the coolant channels and the reaction channels are arranged approximately 90° to each other (in particular between 90° and 80° to each other) and the channels each run in a straight line.
  • variants are conceivable in which, for example, holes exist in the individual plates that allow a transverse distribution through the block (in the stacking direction), or milled grooves are drawn in the diffusion-welded body (longitudinal to the stacking direction), whereby the grooves are sealed by a welded plate.
  • these microreactors also have a large number of individual coolant channels.
  • the term large number in this context means >2, preferably >3, more preferably >4, even more preferably >5, each independently of one another.
  • a reactor unit can comprise several reactor channels, which are then arranged next to one another.
  • the microreactors that can be used in the context of the present invention are preferably made up of several plates stacked on top of one another, with the structures of the plates generally being designed specifically for reaction channels or coolant channels.
  • the respective coolant channels each have their own supply line for the coolant.
  • the supply line can simply be the respective opening of the coolant channel into the reactor.
  • the coolant channels are the The respective individual structures for the flow of coolant and the supply lines to the individual coolant channels are located at their influent end at the edge of the respective levels (i.e. at the reactor edge).
  • the microreactor has a central coolant supply line (connection pipe for the coolants), from which the coolant is distributed to the individual coolant supply lines.
  • microreactors according to the invention have a regulating device for the coolant supply.
  • this regulating device for the coolant supply is a) at least one, preferably exactly one, series resistor based on a microporous structure, which is inserted into the central coolant supply line (the connecting pipe for the coolants) and/or one or more individual coolant supply lines, or b) at least one, preferably exactly one, synchronous flow divider, which is arranged between the central coolant supply line (the connecting pipe for the coolants) and the supply lines to the individual coolant channels, or c) at least one, preferably exactly one, series resistor based on a microporous structure, which is inserted into the central coolant supply line and/or one or more individual coolant supply lines and at least one, preferably exactly one, synchronous flow divider, which is arranged between the central coolant supply line and the supply lines to the individual coolant channels.
  • cooling channels in the direction of reaction progress (inlet of the reaction medium to the outlet) at least two cooling channels (preferably running in cross-flow to the reaction medium in the reactor position), each of which has a series resistance or quantity distributors, arranged in a coolant layer. Then distribution can also take place within the individual cooling channels (for example by branching). Alternatively, all coolant channels can have an individual series resistance (see also below).
  • a central coolant supply line this means the supply line by which the coolant is guided up to just before the supply lines to the individual coolant channels (or up to just before the synchronous flow divider); between the central coolant supply line and the supply lines to the individual coolant channels there is a distribution space which is communicatively connected only to the central coolant supply line and the (individual) supply lines to the individual coolant channels (where the distribution space can have a minimal volume, in some preferred embodiments the volume can be 0), for example a half-pipe closed at the ends, which is welded or sealed to the outer surfaces of the reactor, across the stack, or a cylindrical or otherwise shaped cavity which is formed by cutouts in the individual, superimposed sheet metal layers by diffusion welding, which is placed over the coolant channels to be supplied (where this preferably involves distribution across the stack direction, which can take place inside or outside the plate stack; inside there can be holes or cutouts of any shape, outside the welded half-pipes).
  • the regulating device for the coolant supply is designed as a removable module.
  • These embodiments of the present invention can be referred to as a cooling system according to the invention, in particular when the regulating device for the coolant supply is designed with, for example, hoods, so that it can be placed on microreactors of different dimensions.
  • the regulating device for the coolant supply is permanently installed with the microreactor of the present invention.
  • the porous series resistor is selected such that its resistance is at least three times, preferably at least four times, more preferably at least five times, and at most ten times as high for the liquid coolant flow through the porous series resistor as the resistance that would occur if the target mass flow of coolant specified for the reactor were to flow through the reactor in gaseous state with uniform distribution over all coolant channels, whereby the coolant is preferably water.
  • the cooling medium can flow through the devices according to the invention, for example with a purely liquid phase, for example 0.001 bar to 0.1 bar, with wet steam or in the vaporized state 0.1 bar to 4 bar pressure. These are values without a series resistance. In principle, all cooling medium partial flows have the same pressure loss through the common supply and discharge lines. The different resistance of liquid and wet steam or liquid and gas at the same mass flow results in a different mass flow. This is evened out by the series resistance by installing a high resistance for the incoming liquid phase, i.e. at least three times greater than the resistance in the gaseous state in the reactor, which significantly reduces the difference in the flowability in partial flows.
  • porous series resistor consists of rust-proof material, preferably stainless steel, in particular selected from the group consisting of 1.4404, 1.4751, 1.4539 and nickel-based alloys (e.g. trade names Inconel, Hastelloy, Nicrofer). It is further preferred if these materials are also present as sintered stainless steels.
  • stainless steel in particular selected from the group consisting of 1.4404, 1.4751, 1.4539 and nickel-based alloys (e.g. trade names Inconel, Hastelloy, Nicrofer). It is further preferred if these materials are also present as sintered stainless steels.
  • this porous series resistor can be inserted into the central coolant supply line in various ways.
  • the porous series resistor in a similar way to a frit, ie the porous base body is used as such, or it is covered by a non-permeable jacket (which is in particular ring-shaped).
  • This jacket can then either be placed on a supply line piece or, if the outer diameter of the jacket is adapted accordingly, inserted into the supply line.
  • the porous base body is used as such, it can also simply be inserted/pushed into a supply line piece, whereby it is preferred if retaining devices are provided in the supply pipe.
  • the porous base body fits so tightly into the supply pipe that no cooling medium can flow past it, but only through it.
  • this can be done either via screw connections or screwing into the supply line, or by gluing or simply by clamping or clamping, and preferably by cold or hot pressing.
  • the porous series resistor cannot slip during operation and that no incorrect currents can flow past it.
  • it is just as possible to manufacture the central coolant supply line (the same as the connection pipe for the coolant supply line) directly in such a way that the porous series resistor is incorporated into it.
  • a preferred embodiment of the present invention is a small piece of pipe into which a porous structure is incorporated, preferably sintered.
  • this piece of pipe has connections at both ends, preferably clamp connections or screw connections, in particular screw connections, which are configured in such a way that they can be easily connected or screwed to standardized or already existing supply lines, if necessary via simple adapters.
  • the advantage of this configuration is the interchangeability of the porous structure, in particular when the pores are blocked by dirt or, for example, when the porosity and thus the resistance changes due to corrosion of the material.
  • the setting of the exact resistance of the porous resistor can thus - as is readily known to the person skilled in the art - be regulated, for example, by selecting the porosity of the material accordingly, for example the pore size, the porosity £ [%] according to DIN ISO 30911-3, flow coefficients, etc., or by varying the thickness of the porous layer in the supply pipe.
  • the porous series resistor has one or more, in particular all, of the following features: consists of sintered stainless steel powder; has a porosity £ [%] according to DIN ISO 30911-3 between 20 and 40; has flow coefficients o [10 12 m 2 ] or ß [IO -7 m] according to DIN ISO 4022 between 0.1 and 10 or 0.03 and 30; has a pore size distribution with the characteristics dmin [pm] between 1 and 10 and dmax [pm] between 5 and 30; has a laminar diameter di £ [
  • _im] between 5 and 20; has a degree of separation x T ioo% absolute) [pm] between 3.5 and 107; has a bubble point pressure Ap [mbar] between 83 and 3.0; has a shear strength T [N/mm2] of at least 50 or at least 200, and preferably at most 400 or up to at most 500, in particular at least 50 and at most 400.
  • the dimensions of the porous series resistors used are calculated using the following formula: where o: flow coefficient of the series resistance with respect to viscosity [m]; ß: flow coefficient of the series resistance with respect to density [m]; s: filter thickness [m];
  • V point volume flow [m 3 /s]
  • p fluid density of the coolant to be added [kg/m 3 ]
  • the flow coefficient is a prefactor that establishes an empirical correlation between volume flow and pressure loss in porous bodies in connection with individual material properties of the fluid.
  • a flow divider is a device, preferably self-regulating, that divides an incoming input stream into two or more equal output streams.
  • a synchronous flow divider therefore realizes an equal distribution of material flow to individual sub-strands, which could or would otherwise be unequally loaded.
  • Such devices and their designations are widespread and well-known in technology.
  • Such devices which can also be used in embodiments of the present invention, are available for example as oil flow dividers for hydraulic systems from Jahns or linear stroke flow dividers, which are known as metering cylinders in hydraulics (e.g. Heiss Hydraulik+Pneumatik).
  • synchronous flow divider is selected from the group consisting of gear flow dividers, flow divider valves and piston flow dividers.
  • Gear flow dividers are particularly preferred here. It is particularly preferred if the flow dividers have at least three partial flows.
  • a preferred variant of the present invention is a microreactor in which coolant is passed through the reactor in cross-flow to the reaction medium; which, in addition to a large number of individual reactor units, has a large number of separate coolant channels; wherein the coolant channels each have their own supply line for the coolant; and wherein the microreactor has a central coolant supply line, from which the coolant is distributed to the individual supply lines, comprising a regulating device for the coolant supply, characterized in that as a regulating device for the coolant supply a) at least one series resistor based on a microporous structure is inserted into the central coolant supply line and/or one or more individual coolant supply lines, or b) at least one synchronous flow divider is arranged between the central coolant supply line and the supply lines to the individual coolant channels, or c) at least one series resistor based on a microporous structure is inserted into the central coolant supply line and/or one or more individual coolant supply lines and at least one
  • Flow divider with 10-100 l/min total fluid flow of the coolant for example, with a flow of 0.735 l/min of water, which is to flow through a series resistor, for example, five synchronous flow dividers result in a total of 3.675 l/min per individual reactor base body from one side (in this example, a base body consists of 28 individual reactors, each consisting of a cooling layer and several surrounding reaction layers) and in a reactor scaled to 1.25 MW 1.25 MW, where for example there are 12 individual sides, so a total of 44.1 l/min of water; typical operating pressure 10-40 bar g ;
  • Pressure difference between reaction and cooling 2 bar to 10 bar; at the same theoretical flow rate, the difference in pressure loss between two cooling medium partial flows in two adjacent chambers is between 0.1 bar and 4 bar; maximum pressure difference across the flow divider: the flow flowing out of the flow divider has a temperature of preferably 5°C (3-10°C) below boiling temperature at a given pressure in the reactor;
  • the series resistance for the liquid coolant is at least four times the resistance of the gaseous coolant as it flows through the reactor, it is guaranteed that the partial flow can change by a maximum of 20% compared to other partial flows, so that the window of a maximum of 60% steam content for each partial flow (i.e. each coolant channel) at setpoints of 15-40% is not exceeded.
  • a further advantage of this inventive procedure for regulating the coolant supply is that the microporous series resistor also serves to protect the microstructures of the coolant channels (coolant structures) from the ingress of foreign particles.
  • protection of the series resistors by filters is preferred in some embodiments of the present invention.
  • a specific resistance of about 2 bar with an expected pressure loss of up to 0.5 bar for the gaseous cooling medium is preferred in order to ensure the economic efficiency of the cooling.
  • the series resistance is primarily used for water with boiling pressures in the If a pressure range of 15 to 40 bar is used, the boiling temperature of the coolant at the reactor must be at least 5°C below the boiling point. The higher pressure before the series resistor effectively prevents the risk of pre-evaporation in electrical or recuperative heat exchangers.
  • the inlet temperature into the reactor is preferably precisely controlled to avoid cavitation at the series resistor due to the pressure drop that occurs there, in particular to a temperature of 2°C to 15°C, preferably 5°C to 10°C, below the boiling point.
  • the supply of the reaction media into the reaction channels is regulated in the same way as the coolant supply, i.e. via microporous series resistors and/or synchronous flow dividers.
  • the present invention further relates to a method for cooling exothermic reactions taking place in a microreactor.
  • This method is preferably applied to the microreactors according to the invention, as described above.
  • features described for the microreactors according to the invention or those described for the methods according to the invention are also applicable to the other objects according to the invention (including uses, etc.), unless this obviously contradicts one another.
  • This method comprises several steps: i) passing coolant in cross-flow to the reaction medium through the microreactor, which has a large number of separate coolant channels in addition to a large number of individual reactor units, wherein the coolant channels each have their own supply line for the coolant and a central coolant supply line from which the coolant is distributed to the individual supply lines. ii) regulating the coolant flow through the coolant channels by regulating the coolant supply.
  • This method according to the invention is characterized in that the coolant supply is also regulated here in accordance with the above statements by a) passing the coolant through a series resistor based on a microporous structure inserted into the central coolant supply line (equal to the connecting pipe) and/or one or more individual coolant supply lines, or b) passing the coolant through a synchronous flow divider arranged between the central coolant supply line and the supply lines to the individual coolant channels, or c) passing the coolant through a series resistor based on a microporous structure inserted into the central coolant supply line and/or one or more individual coolant supply lines and passing the coolant through a synchronous flow divider arranged between the central coolant supply line and the supply lines to the individual coolant channels.
  • the coolant is adjusted to a temperature close to its boiling point before being passed over the series resistor (or through the series resistor) and/or the synchronous flow divider.
  • This temperature is preferably set to a maximum of 3°C below the boiling point, more preferably at least 5°C below the boiling point, even more preferably at least 8°C below the boiling point and at most 15°C below the boiling point, more preferably at most 10°C below the boiling point. It is also preferred, particularly in connection with these temperatures, that the coolant has a pressure of 5 bar to 80 bar, in particular 15 bar to 40 bar, before being passed over the series resistor (or passed through the series resistor) and/or the synchronous flow divider.
  • the resistance of the gaseous coolant as it flows through the reactor is determined and the porous series resistor is adjusted so that its resistance is at least three times, preferably at least four times, more preferably at least five times, at most ten times as high as the resistance of the gaseous coolant as it flows through the reactor, wherein the coolant is preferably water.
  • the microreactor is designed in such a way that it has coolant supply lines into the coolant channels on more than one side, preferably on two sides, in particular opposite sides, so that the supplied coolant flows through the microreactor in more than one direction, in each case in cross-flow to the reaction medium.
  • the reaction medium flows in one direction, for example from above, where it is fed into the reactor inflow, downwards through the reactor.
  • the coolant flowing in cross-flow to the reaction medium is then guided into and through the reactor not only from one side, but from more than one side.
  • the flow directions of the coolant can alternately flow through successive coolant (medium) levels in opposite directions.
  • other embodiments are also possible, for example groups of levels such as three levels in which the coolant flows in one direction, then three levels in which the coolant flows in another direction, or also, for example, with three levels in one direction and then with one (or two, or four, etc.) in the other, etc.
  • the central coolant supply is divided between the individual supply lines, as in the other variants according to the invention with "only" one-sided coolant supply.
  • the coolant is supplied from more than one side, preferably two sides.
  • a portion of the coolant is supplied to the reactor from the left, for example, and another portion from the right, for example.
  • the quantities can be the same, which is preferred in some embodiments, or they can be different. The person skilled in the art will adapt this depending on the conditions and/or requirements in each case.
  • the regulating devices according to the invention are then assigned to the individual supply lines.
  • the present invention further relates to a method for controlling the reactor operation and/or the coolant supply, in particular in or for a microreactor according to the invention.
  • This method is characterized in that the coolant supply is regulated by a) passing the coolant through a series resistor based on a microporous structure inserted into the central coolant supply line (equal to the connecting pipe) and/or one or more individual coolant supply lines, or b) passing the coolant through a synchronous flow divider arranged between the central coolant supply line and the supply lines to the individual coolant channels, or c) passing the coolant through a series resistor based on a microporous structure inserted into the central coolant supply line and/or one or more individual coolant supply lines and passing the coolant through a synchronous flow divider arranged between the central coolant supply line and the supply lines to the individual coolant channels.
  • the method according to the invention is further characterized in that the Coolant is passed through the microreactor from more than one side, preferably from two sides, in particular opposite sides, via the individual coolant supply lines, so that the supplied coolant flows through the microreactor in more than one direction, in each case in cross-flow to the reaction medium.
  • the present invention relates to the use of a microreactor according to the invention or of a process according to the invention for or in Fischer-Tropsch reactions, methanol synthesis reactions or methanation reactions from CO, CO2 or mixtures thereof.
  • a series resistor based on a microporous structure is arranged only in the central coolant supply line, but not in any of the individual coolant supply lines.
  • a series resistor based on a microporous structure is arranged in one of the individual coolant supply lines, but not in the central coolant supply line.
  • series resistors based on a microporous structure are arranged in several of the individual coolant supply lines, but not in the central coolant supply line.
  • series resistors based on a microporous structure are arranged in all individual coolant supply lines, but not in the central coolant supply line.
  • series resistors based on a microporous structure are arranged in the central coolant supply line and in one of the individual coolant supply lines.
  • series resistors based on a microporous structure are arranged in the central coolant supply line and in several of the individual coolant supply lines.
  • the series resistor in the central coolant supply line generates a pressure loss of 0.5 bar to 7 bar, particularly preferably from 1 bar to 5 bar, in particular preferably from 2 bar to 4 bar.
  • the series resistor or the series resistors in one or more or all individual coolant supply lines generate or generate a pressure loss of 0.5 bar to 2 bar, particularly preferably from 0.7 bar to 1.5 bar, in particular 1 bar.
  • the series resistor in the individual coolant channel corresponding to the zone with the highest reaction temperature generates an additional pressure loss which is between 15% and 35%, particularly preferably 20% to 30% and in particular 25%, of the pressure loss generated by the series resistor in the central coolant supply line.
  • Each of these variants can be combined with one or more synchronous flow dividers.
  • the present invention also encompasses the use of series resistors or synchronous flow dividers in the sense of the present invention when distributing coolant between different microreactors.
  • the present invention is characterized in that, on the one hand, synchronous flow dividers for coolant regulation, in particular coolant regulation with evaporative cooling, are arranged along the reactor length of Microreactors and parallel reactors were not known from the state of the art.
  • the present invention requires significantly less control effort for the parallelization of reactor modules and the coolant distribution.
  • the present invention is very advantageous in terms of equipment. Furthermore, this also directly results in a cost advantage that cannot be ignored.
  • the present invention relates in particular to a very specific application, namely that the coolant for cooling the reactor is operated in a state in which a certain proportion of the coolant in the coolant channels is intentionally evaporated. This evaporation ensures that particularly good cooling is achieved due to the evaporation enthalpy. As explained above, it is problematic in the current state of the art to maintain this state for all coolant channels along the length of the reactor (corresponding to the different temperatures along the reactor or the reactor channels).
  • a further simplification for cooling the reactor is the two-sided loading, in which the plates with the coolant supply lines are stacked in such a way that the coolant flows alternately in opposite directions through the coolant supply lines.
  • the counterflow of the coolant in separate chambers, which are connected to each other via the metallic connection via the reaction channels, prevents particularly hot reactor zones from due to premature heating and evaporation in the coolant supply lines over the length of the reactor width, which reduces the cooling capacity in the evaporation structures provided for this purpose.
  • the two-sided feed is preferably combined with the series resistors in the central or individual coolant supply lines and/or the synchronous flow divider.
  • the coolant that can be used according to the invention can be selected from a large number of known coolants. It is clear and known to the person skilled in the art that it has to be adapted to the reaction to be cooled (or its reaction heat) and the geometries of the coolant channels (substances that are too viscous flow poorly through channel diameters that are too small).
  • the coolant is selected from the group consisting of water, ammonia, propane, butane, glycol, fluorinated and/or chlorinated hydrocarbons or mixtures thereof. Water is particularly preferred as a coolant in the context of the present invention.
  • the individual parts of the devices are operatively connected to one another in a conventional and well-known manner.
  • Figure 1 shows an example of a reactor of the prior art.
  • the image shown here corresponds to Figure 1 of WO 2017/013003.
  • This figure illustrates that microreactors, as they are generally used, can be constructed from several different structural layers arranged one above the other. Different layers are structured to form coolant channels in the finished reactor, while other layers are structured to form reaction channels in the finished reactor. Since this figure is only intended to illustrate that the microreactors of the present invention are preferably constructed from several layers or layers arranged one above the other and not to represent the specific structures of the layers, no reference numbers are given in the version of Figure 1 of WO 2017/013003 reproduced here.
  • Figure 2a shows a top view of a reactor level or reactor layer or reactor layer 1, in which the reaction medium flows in from the top in the figure and the reacted reaction medium flows out on the lower side in the figure.
  • the structured area in the middle schematically represents the catalyst bed along which the reaction medium flows, but the invention is not limited to specific structures or embodiments for the catalyst bed. Rather, the structures for the reactor level/reactor layer can be widely can be varied and in principle have all structures known from the prior art, for example in the simplest case also simple channels (as already indicated by the lines at the upper and lower ends in Figure 2a).
  • Number 8 in Figure 2a on the left side indicates five circular inlets for coolant (supply lines or openings) to the respective coolant channels.
  • number 9 indicates a recess/an elongated outlet slot which serves as an outflow for the heated (partially evaporated) coolant. This figure therefore describes the flow direction of the reaction medium.
  • Figure 2b is also a top view of a reactor like Figure 2a, except that this time the top view is of a cooling level and not a reaction level. It is illustrated that the coolant is fed in from the left (i.e. in crossflow to the flow direction of the reaction medium in level 1) and then the individual coolant flows Kl to K5 flow through the cooling level/cooling layer/cooling layer 2 from left to right. This figure illustrates that the individual cooling channels are not just straight channels, but can have branches to the sides (e.g. H-shaped).
  • the top coolant Kl is how this coolant runs through the coolant level shown; it runs from left to right, then reaches the top via the H-shaped distributor functions (in the picture) and then finally further to the right to the slot-shaped coolant outlet 9, where the collected coolant exits the reactor K out .
  • this one coolant path shown in bold is only an example.
  • the coolant is also distributed in the other H-shaped coolant distributors in the other directions, i.e. to the left and right as well as up and down.
  • the possibility of structuring the cooling level 2 shown here is of course only to be understood as an example; the expert is aware of a wide variety of other coolant level structures. This figure therefore describes the flow direction of the cooling passage via communicating tubes and, as an example, the supply of a microstructure for the cooling level.
  • Figure 3a corresponds essentially to Figure 2a, with the difference that a region ZK+ is drawn in, which is intended to illustrate a zone of increased catalyst activity.
  • the zone of increased catalyst activity corresponds to a zone of increased reaction enthalpy. For example, this can occur when a fresh catalyst is used that is still particularly active and catalyzes the respective reaction particularly well.
  • FIG 3b again shows a cooling level 2, which essentially corresponds to the cooling layer or cooling level 2, as illustrated in Figure 2b.
  • This figure also illustrates a zone Zv+, which is essentially congruent (seen from above) with the zone of increased catalyst activity Z K+ illustrated in Figure 3a.
  • the zone Zv+ illustrated here is a zone of increased evaporation of the coolant, which results from the increased reaction temperature or increased reaction enthalpy released in the zone ZK+. This increased evaporation results in an increased flow resistance for the coolant in this area and in an increased vapor pressure (Ap D at P f).
  • Figure 3c again shows a corresponding cooling level 2, where the flow of the coolant is again illustrated from the left inflowing K and from the right outflowing K.
  • the thinner arrow or the thinner line thickness with respect to the coolant partial flow K2 illustrates that in this area, which corresponds to the zones Z K+ and Z v+ , there is an increased proportion of steam, the flow velocity would have to increase accordingly and therefore less coolant can flow through in comparison to the other coolant partial flows K1 and K3 to K5. This is therefore the situation that is disadvantageous and is to be avoided by the present invention.
  • Figure 4 illustrates the variant according to the invention of passive control of the pressure of the coolant flow or the coolant flows by means of series resistors.
  • a series resistor is placed before the distribution of the coolant flow K on the individual coolant flows.
  • the series resistor which regulates the pressure of the incoming coolant Kein, ensures that the various partial flows of the coolant Ap vor are equal, which is illustrated by the same arrow or line thickness. This is because the use of the series resistor reduces the relative flow resistance in the individual coolant channels, which correspond to communicating tubes.
  • Figure 5 shows the flow conditions in a coolant plane, similar to Figure 4, although here too the same zone of increased evaporation with increased flow resistance for coolant is present.
  • Figure 5 shows the second variant of the present invention, namely the active flow application by means of a synchronous flow divider.
  • the incoming coolant K is regulated, but here by setting the coolant pressure to a certain pressure p S0 n by means of a synchronous flow divider, so that the individual partial coolant flows are of equal strength, which in turn is illustrated by the same arrow thickness or line thickness. It is therefore shown that the flow in this case is independent of the flow resistance due to evaporation.
  • FIG. 6 illustrates a cross section through a central coolant supply line (a connecting pipe) 3, into which a porous series resistor 4 is inserted or clamped.
  • a central coolant supply line a connecting pipe
  • FIG. 6 it is illustrated that one part of the connecting pipe 3 has a zone 5 with a widened inner diameter, into which the porous series resistor 4 is inserted.
  • This variant of the central supply line or the connecting pipe 3 and the corresponding arrangement of the porous series resistor 4, i.e. by clamping it in an area with a widened inner diameter has the advantage that the flow of the coolant always holds the porous series resistor in place, since it does not fit through the narrower diameter of the connecting pipe 3 outside the zone 5.
  • the porous series resistor is not introduced into the connecting pipe 3, but is applied as a kind of plug to the end of the connecting pipe 3, for example by gluing, screwing or clamping.
  • Figure 7 shows an example of an embodiment of the series resistor according to the invention, which is designed as a series resistor adapter piece 7.
  • the connecting pipe 3 is designed similarly to that in Figure 6, ie the porous series resistor 4 is located inside the connecting pipe 3.
  • screw connections, nuts or clamp connections 6 are also indicated, with the help of which this series resistor adapter piece 7 can be screwed or clamped onto an existing central coolant supply line of a reactor on one side and the general coolant supply on the other side.
  • This figure also indicates where the zone with an expanded inner diameter 5 is located.
  • FIG. 8 shows a highly schematic representation of the pressure loss magnitudes along the flow direction of the cooling medium in a variant of the use of the porous series resistors according to the invention.
  • the pressure is plotted on the vertical axis and the distance of the flow on the right-hand axis (in each case without special units).
  • the series resistor is located in section A; where AO is the beginning of the common line.
  • Section B is the common supply line to a plurality of coolant channels in a cooling (medium) layer.
  • the dashed line D shows the pressure curve in an almost liquid state in the reactor (section C) and the solid line E shows the pressure curve with strong evaporation in the reactor for the relevant zone of increased evaporation Z v+ .
  • the slope of the straight line in section C is small compared to that in section A.
  • the pressure ratio G: F is equivalent to the drop in the coolant mass flow in the cooling (medium) layer Z v+ compared to other cooling (medium) layers.
  • Figure 9 shows an arrangement of several microreactors I to VI arranged next to one another, which are enclosed by an upper cover 13 and a lower cover 14.
  • reaction medium that is fed in through the reactor inflow 12 clean
  • product emerging from the microreactors I to VI is received and distributed and/or collected in the lower cover 14 (also not shown).
  • the various microreactors I to VI are connected to one another or fastened to one another using fastening/connecting devices 12.
  • the entire arrangement can also be fastened to a frame or similar, for example, using the outer fastening/connecting devices 12 (this would be on the right and left outside in the picture, but is not shown); the screws (or other fastening means such as rivets) 10 serve to securely connect the cover 13, 14 to the microreactors I to VI.
  • This figure also illustrates how inflowing coolant K is introduced into the supply lines 8 to the individual coolant channels.
  • the series resistors and/or synchronous flow dividers to be used according to the invention would either be located in the inflow-side ends of the supply lines 8 (i.e. in particular the sections shown thicker) or upstream of them and connected to them via connecting elements; For the sake of clarity, series resistors and/or synchronous flow dividers are not shown in this figure.
  • FIG 10 is a simplified cross-sectional view through a microreactor schematically illustrating a variant according to the invention.
  • the reaction medium flows from above, where it is fed into the reactor inlet 12, downwards through the reactor (from R in to R out ).
  • the coolant flowing in cross-flow to the reaction medium is guided into/through the reactor not only from one side, but from two sides.
  • four levels 2 are shown in the figure for simplicity, through which the coolant flows in the direction from K in to K out .
  • the flow directions are shown alternating, but other embodiments are also possible, for example groups of levels such as three levels in one direction, then three in the other, or focal points such as three in one direction and one in the other, etc.

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Abstract

L'invention concerne des microréacteurs comprenant un dispositif de commande pour l'alimentation en liquide de refroidissement, au moins une pré-résistance, qui est basée sur une structure microporeuse, étant insérée dans la conduite d'alimentation en liquide de refroidissement centrale et/ou une ou plusieurs conduites d'alimentation en liquide de refroidissement individuelles, et/ou au moins un diviseur d'écoulement synchrone étant agencé entre la conduite d'alimentation en liquide de refroidissement centrale et les conduites d'alimentation vers les canaux de liquide de refroidissement individuels. L'invention concerne également un procédé de refroidissement de réactions exothermiques se produisant dans un microréacteur et de commande du fonctionnement du réacteur et/ou de l'alimentation en liquide de refroidissement au moyen d'un processus de commande correspondant de l'alimentation en liquide de refroidissement et des applications correspondantes.
PCT/EP2024/072608 2023-08-10 2024-08-09 Commande de l'alimentation en liquide de refroidissement dans des microréacteurs Pending WO2025032231A1 (fr)

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