A flow reactor or flow reactor component includes a base plate, a first fluid module having first and second major surfaces, an internal process fluid passage, and a heat exchange channel in the first major surface, the first major surface stacked on the base plate; a second fluid module having first and second major surfaces, an internal process fluid passage and a heat exchange channel in the first major surface, the first major surface stacked on the second major surface of the first fluid module, optional additional fluid modules of the same configuration as the first and second fluid modules stacked successively on the second fluid module, and a top plate having a heat exchange channel in a bottom major surface thereof with the bottom major surface stacked on an uppermost fluid module of (1) the second fluid module and (2) the optional additional fluid modules.

The invention provides methods of making laminated devices (especially microchannel devices) in which plates are assembled and welded together. Unlike conventional microchannel devices, the inventive laminated devices can be made without brazing or diffusion bonding; thus providing significant advantages for manufacturing. Features such as expansion joints and external welded supports are also described. Laminated devices and methods of conducting unit operations in laminated devices are also described.

Modular reactors comprising a chassis, reactor tubing and optionally a cover are disclosed. The chassis comprises a plurality of channels of different lengths into which a length of reactor tubing is placed to create the reactor portion of the flow reactor.

According to some aspects, described herein is an automated droplet-based reactor that utilizes oscillatory motion of a droplet in a tubular reactor under inert atmosphere. In some cases, such a reactor may address current shortcomings of continuous multi-phase flow platforms.

A method of loading material within a microchannel device, the method comprising: (a) loading particulates into a plurality of microchannels; and, (b) ultrasonically packing the particulates into the plurality of microchannels using a portable, compact ultrasonic densification unit.

A reactor system for high throughput applications includes a plurality of reactor assemblies, each reactor assembly including: a fluid source, which fluid source is adapted to provide a pressurized fluid to the flow-through reactors, a flow splitter which flow splitter includes a planar microfluidic chip, which microfluidic chip has a chip inlet channel and a plurality of chip outlet channels, which microfluidic chip further includes a plurality of flow restrictor channels, where each flow restrictor channel extends from said chip inlet channel to an associated chip outlet channel, where the chip inlet channel and the chip outlet channels each have a diameter, where the diameter of the chip inlet channel is the same or less than the length of said chip inlet channel and where the diameter of each chip outlet channel is the same or less than the length of said chip outlet channel.

A flow reactor fluidic module (12) includes a reactant fluid module (20) having an internal process fluid passage (22) and a first major planar outer surface (24a) and a thermal resistance R between the internal process fluid passage (22) and the first major planar surface (24); a thermal control fluid module (30) having an internal thermal control fluid passage (32) and a second major planar outer surface (34a); a holding structure (50) holding the reactant fluid module (20) and the thermal control fluid module (30); and a gap (25) separating the first major planar surface (24a) from the second major planar surface (34a). The gap (25) comprises an interchangeable or replaceable substance or sheet (26) having a thermal resistance G across the gap (25), wherein G is not equal to R.

A method of loading material within a microchannel device, the method comprising: (a) loading particulates into a plurality of microchannels; and, (b) ultrasonically packing the particulates into the plurality of microchannels using a portable, compact ultrasonic densification unit.

The invention provides methods of making laminated devices (especially microchannel devices) in which plates are assembled and welded together. Unlike conventional microchannel devices, the inventive laminated devices can be made without brazing or diffusion bonding; thus providing significant advantages for manufacturing. Features such as expansion joints and external welded supports are also described. Laminated devices and methods of conducting unit operations in laminated devices are also described.

A flow reactor fluidic module (12) includes a reactant fluid module (20) having an internal process fluid passage (22) and a first major planar outer surface (24a) and a thermal resistance R between the internal process fluid passage (22) and the first major planar surface (24); a thermal control fluid module (30) having an internal thermal control fluid passage (32) and a second major planar outer surface (34a); a holding structure (50) holding the reactant fluid module (20) and the thermal control fluid module (30); and a gap (25) separating the first major planar surface (24a) from the second major planar surface (34a). The gap (25) comprises an interchangeable or replaceable substance or sheet (26) having a thermal resistance G across the gap (25), wherein G is not equal to R.