Biphasic Plasma Microreactor and Method of Using the Same
20210051789 · 2021-02-18
Inventors
- Julien Wengler (Paris, FR)
- Stéphanie Ognier (Paris, FR)
- Safwan Al Ayoubi (Wattignies, FR)
- Michael Tatoulian (Paris, FR)
Cpc classification
B01J19/0093
PERFORMING OPERATIONS; TRANSPORTING
B01J2219/0805
PERFORMING OPERATIONS; TRANSPORTING
B01J19/088
PERFORMING OPERATIONS; TRANSPORTING
H05H1/2406
ELECTRICITY
B01J2219/0894
PERFORMING OPERATIONS; TRANSPORTING
H01J37/20
ELECTRICITY
International classification
H01J37/20
ELECTRICITY
Abstract
The present invention relates to a plasma reactor and more specifically to an plasma microreactor comprising a support, made at least partially of a dielectric material, the support comprising a gas inlet, a liquid inlet, at least a fluid outlet, a liquid microchannel in the support, a gas channel, at least a ground electrode, at least a high voltage electrode, separated from the gas channel by the dielectric material of the support, wherein said ground electrode and said high voltage electrode are arranged on opposite sides of the gas channel so as to be able to create an electric field inside the gas channel, wherein the liquid microchannel and the gas channel are contiguous and at least an opening is arranged between the liquid microchannel and the gas channel so as to form a fluid channel and to cause the liquid flow contact the gas flow and wherein the liquid flow is retained within the liquid microchannel by capillarity action.
Claims
1. A plasma microreactor (1) comprising: a support (3), made at least partially of a dielectric material, the support comprising a gas inlet (13), adapted to be connected to a gas reservoir (19), a liquid inlet (14), adapted to be connected to a liquid reservoir (20) and at least a fluid outlet (15) adapted to be connected to a receiver containing gas and/or liquid, a liquid microchannel (9) in the support (3) adapted to allow a liquid flow from the liquid inlet to the fluid outlet (15), a gas channel (10), in the support (3) adapted to allow a gas flow from the gas inlet to the fluid outlet (15), at least a ground electrode (4), at least a high voltage electrode (5), separated from the gas channel by the dielectric material of the support, wherein said ground electrode (4) and said high voltage electrode are arranged on opposite sides of the gas channel (10) so as to be able to create an electric field inside the gas channel (10), wherein the liquid microchannel and the gas channel are contiguous and at least an opening is arranged between the liquid microchannel and the gas channel so as to form a fluid channel (2) and to cause the liquid flow contact the gas flow and wherein the liquid flow is retained within the liquid microchannel by capillarity action.
2. The plasma microreactor of claim 1, wherein at least one, and notably one, opening (11) is arranged between the liquid microchannel (9) and the gas channel (10) on at least 80%, notably 90%, such as about 100%, of the length of the fluid channel (2).
3. The plasma microreactor of claim 1 or 2, wherein the opening (11) is partially defined by a convex bended portion (7) of a wall of the fluid channel (2), said bended portion (7) being arranged between the liquid microchannel (9) and the gas channel (10) and extending continuously along the length of the liquid microchannel and along the length of the gas channel.
4. The plasma microreactor according to any one of claims 1 to 3, wherein the convex bended portion (7) has a radius of curvature being less than 20 m.
5. The plasma microreactor according to any one of the claims 1 to 4, comprising a high voltage source (6) electrically connected to the ground electrode(s) (4) and to the high voltage electrode(s) (5).
6. The plasma microreactor according to any one of the claims 1 to 5, wherein the length of the liquid microchannel (9) and the length of the gas channel (10) are over 2 cm, notably over 20 cm and preferably over 100 cm.
7. The plasma microreactor according to any one of the claims 1 to 6, wherein the support is made of a UV-cured polymer such as a polymer obtained by photopolymerisation of a thiol-ene based resin, a poly(tetramethylene succinate), a cyclic olefin copolymer (COC) such as a copolymer of ethylene and norbornene or tetracyclododecene, glass, a ceramic material, or a combination thereof.
8. The plasma microreactor according to any one of the claims 1 to 7, wherein the fluid channel (2) is arranged following a main plane, the design of the fluid channel allowing to have a surface density of the fluid channel in said plane higher than 0,3 over a square of 20 mm.sup.2 or more, said fluid channel 2 being notably arranged in a serpentine pattern.
9. The plasma microreactor according any one of claims 1 to 8, wherein the liquid microchannel (9) has a smaller height than the gas channel (10) so as to form a step between the liquid microchannel and the gas channel.
10. The plasma microreactor according to anyone of the claims 1 to 9, wherein two liquid microchannels (9) are arranged on opposite sides of the gas channel (10), so that the fluid channel (2) has a T-shaped section.
11. The plasma microreactor according to anyone of the claims 1 to 10, wherein the support (3) is entirely made of glass or ceramic material or at least made of a polymeric layer comprised between two glass layers.
12. The plasma microreactor according to anyone of the claims 1 to 11, wherein the height of the liquid microchannel (9) is more than 1 m, notably more than 10 m, preferably more than 40 m and is less than 200 m, notably less than 100 m, preferably less than 50 m, and/or wherein the height of the gas channel (10) is comprised between the height of the liquid microchannel (9) and 1 mm, notably between the height of the liquid microchannel (9) and 200 m and preferably between the height of the liquid microchannel (9) and 100 m.
13. A method for generating a plasma in a plasma microreactor (1), comprising the steps of: (a) providing a plasma microreactor according to any of the claims 1 to 12, (b) providing a liquid (8) and making the liquid flow through the liquid microchannel(s) (9) in a given direction, (c) providing a gas (12) and making the gas flow through the gas channel (10) in said direction, (d) applying a high voltage between the high voltage electrode(s) (5) and the ground electrode(s) (4) so as to generate a plasma in the gas channel (10).
14. The method of claim 13, wherein the gas flow rate through the gas channel (10) is higher than the liquid flow rate through the liquid microchannel (9), preferably between 5 times and 10000 times the liquid flow rate in the liquid microchannel (9).
15. The method according to claim 13 or 14, wherein the gas is selected from air, argon, helium, oxygen, hydrogen, nitrogen, water vapor, ammoniac, carbon dioxide, carbon monoxide, volatile hydrocarbons such as methane, volatile organic compounds and a mixture thereof and/or wherein the liquid is selected from solvents, more particularly from organic or aqueous solvents, such as water, an aliphatic hydrocarbon, an aromatic hydrocarbon, an alcohol, an ether, an ester, a ketone, a halogenated solvent, dimethylsulfoxide (DMSO), acetonitrile, dimethylformamide (DMF), an ionic liquid or a mixture thereof; and reagents such as methyl methacrylate (MMA) or phenol; or a mixture thereof.
16. The method according to any one of claims 13 to 15, wherein the high voltage is comprised between 250 V and 30 kV, notably between 1 kV and 20 kV, preferably between 1 kV and 10 kV and wherein the high voltage is a variable, such as sinusoidal, high voltage with a frequency comprised advantageously between 100 Hz and 1 MHz, in particular comprised between 100 Hz and 100 kHz, preferably comprised between 100 Hz and 10 kHz, or the high voltage is a pulsed voltage with a frequency comprised advantageously between 100 Hz and 1 MHz, in particular comprised between 100 Hz and 10 kHz, preferably comprised between 100 Hz and 1 kHz.
17. The method according to any one of claims 13 to 16, wherein a compound present in the liquid (8), such as a solvent or a reagent, is submitted to at least a chemical reaction such as cleaving, oxidation, hydrogenation, dehydrogenation, amination or carbonylation.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] The invention will be described by way of example, with reference to the accompanying drawings in which:
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DETAILED DESCRIPTION OF PREFERRED ASPECTS OF THE INVENTION
[0074] Architecture of the Microreactor
[0075] Referring to
[0076] Dielectric Material
[0077] The support 3 according to the present invention is at least partially made of a dielectric material in order to isolate the gas channel 10, since a high-voltage electric field can be controlled inside the support 3 between the electrodes 4,5. The dielectric material used in the present invention can be any material known for its dielectric properties. However, the dielectric material will be advantageously impervious to gas and liquid which have to flow through the fluid channel comprised in the support 3. Moreover, the dielectric material should also advantageously allow the formation of the support 3 comprising at least a liquid microchannel 9 and a gas channel 10, and for example embedded electrodes. The dielectric material can thus be a UV-cured polymer (i.e. a polymer obtained by photopolymerisation of monomers or prepolymers), such as a polymer obtained by photopolymerisation of a thiol-ene based resin (for example a Norland Optical Adhesive (NOA), such as NOA-81 or NOA-61, preferably NOA-81), a poly(tetramethylene succinate) (PTMS), a cyclic olefin copolymer (COC) such as a copolymer of ethylene and norbornene or tetracyclododecene, glass, a ceramic material, or a combination thereof. In a preferred embodiment of the invention, the support 3 is made of a polymeric layer comprised between two glass layers, for example two glass coverslips. In another preferred embodiment of the invention, the support 3 is entirely made of glass or of ceramic material. In order to form the liquid microchannel(s) 9 and the gas channel(s) 10, glass can be micromachined by chemical wet etching (using HF selective etching for example) and/or laser engraving.
[0078] Liquid Microchannel(s) and Gas Channel(s)
[0079] In all the embodiments of the invention, the support 3 comprises at least a gas channel 10, preferably at least gas microchannel, and at least a liquid microchannel 9 so as to form at least a fluid channel 2, each liquid microchannel 9 being contiguous with a gas channel 10, an opening being arranged between each liquid microchannel 9 and at least a gas channel 10 to cause a liquid 8 in said liquid microchannel 9 to contact a gas 12 in said gas channel 10, the liquid 8 flow being retained within the liquid microchannel 9 by capillarity action.
[0080] In reference to
[0081] The convex bended portion 7 partially defines the opening 11, arranged between the liquid microchannel 9 and the gas channel 10. The convex bended portion 7 is extending continuously along the length of the liquid microchannel 9 and of the gas channel 10. Preferably, the radius of curvature of the convex bended portion 7 is less than 50 m, notably less than 20 m and preferably less than 5 m. Therefore, said convex bended portion 7 is adapted to pin a triple line when a liquid 8 is injected in the liquid microchannel, and to enable the stabilization of a liquid flow in a liquid microchannel 9, and of a gas flow in the gas channel 10, the liquid flow contacting the gas flow at the opening 11.
[0082] The height h.sub.l of the liquid microchannel 9 is comprised between 500 nm and 500 m, notably between 2 m and 200 m and preferably between 5 m and 100 m. The height h.sub.g of the gas channel 10 is comprised between 500 nm and 1 mm, notably between 2 m and 200 m and preferably between 5 m and 100 m.
[0083] In a preferred embodiment, the liquid microchannel 9 can have a smaller height than the gas channel 10, so as to form a step between the liquid microchannel 9 and the gas channel 10. The convex bended portion 7 is, in this case, the edge of the step between the liquid microchannel 9 and the gas channel 10. Therefore, the liquid 8 can be maintained within the liquid microchannel 9 by capillarity action. In reference to
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[0086] The height h.sub.l of the liquid microchannel 9 is advantageously comprised between 500 nm and 500 m, notably between 2 m and 200 m and preferably between 5 m and 100 m. The height h.sub.g of the gas channel 10 is advantageously comprised between 500 nm and 1 mm, notably between 2 m and 200 m and preferably between 5 m and 100 m.
[0087] The liquid microchannel 9 can have a smaller height than the gas channel 10, so as to form two steps between the liquid microchannel 9 and the gas channel 10. The convex bended portions 7 are, in this case, the edges of the steps between the liquid microchannel 9 and the gas channel 10.
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[0090] The liquid microchannels 9 can form a two-dimensional array of liquid microchannels 9, and preferably of parallels liquid microchannels 9, each liquid microchannel being contiguous with the gas channel 10. The array can be arranged underneath the gas channel 10. Therefore, it is possible to parallelize the layout of the openings 11, so as to simplify the fabrication of the plasma reactor 1.
[0091] The height h.sub.l of the liquid microchannel 9 is advantageously comprised between 500 nm and 500 m, notably between 2 m and 200 m and preferably between 5 m and 100 m. The height h.sub.g of the gas channel 10 is advantageously comprised between 500 nm and 1 mm, notably between 2 m and 200 m and preferably between 5 m and 100 m.
[0092] The width w.sub.l of the liquid microchannel 9 is advantageously comprised between 500 nm and 500 m, notably between 2 m and 200 m and preferably between 5 m and 100 m. The width w.sub.g of the gas channel 10 is advantageously comprised between 2 m and 10 mm, notably between 2 m and 1 mm.
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[0094] In a different embodiment of the invention (not shown), the support 3 can comprise a plurality of liquid inlets 14. For example, the support 3 can comprise two liquid inlets 14, adapted to be connected to two liquid reservoirs and respectively to two liquid microchannels 9. Therefore, different liquids 8 can be injected in two different liquid microchannels 9 in contact with the same gas channel 10.
[0095] The fluid channel 2 can be connected to a receiver, containing gas and/or liquid, by the means of a common fluid outlet (not illustrated) of the fluid channel 2. In a different embodiment, illustrated in
[0096] The fluid channel 2 is arranged following a main plan in a serpentine pattern. Therefore, the density of fluid channel 2 for a given surface can be optimized for a predefined microreactor surface. Particularly, the fluid channel 2 length, hence the liquid microchannel 9 length and/or the gas channel 10 length, can be higher than 2 cm, notably higher than 20 cm and preferably higher than 100 cm. This fluid channel 2 length can be higher than 1 m for example in a microreactor made of standard typical glass coverslips of 60 mm by 24 mm.
[0097] Therefore, it is possible to increase the contact surface between the liquid 8 and the gas 12 for a predefined surface, and therefore to increase the efficiency of the plasma microreactor 1. Other patterns of fluid channel 2 can be used, in order to increase the density of fluid channel 2 in the main plane. Multiple parallel fluid channels 2 can be designed for instance. More generally, the surface density of fluid channel 2 in the main plane can be higher than 0.3 over a square of 20 mm.sup.2 or more.
[0098] General Setup
[0099]
[0100] The liquid outlet 15b can be directly connected to an analyzer, in order to analyze the chemical species at the output of the plasma microreactor 1. The liquid outlet 15b can also be connected to another plasma microreactor 1 according to the present invention or not, so as to perform another synthesis step on the liquid issued from the plasma microreactor 1 for example. In another embodiment, the gas outlet 15a and the liquid outlet 15b can be connected to a common receiver.
[0101] The plasma microreactor 1 can be monitored by a computer, specifically adapted to monitor: [0102] pressure controllers 23, which control the pressure of gas 12 upstream the plasma microreactor 1, [0103] a pressure controller and/or an automated syringe driver 20, which controls the pressure and/or the flow rate of the liquid 8 upstream the plasma microreactor 1, [0104] a high voltage source 6 which can be composed of various apparatuses such as a function generator, a signal amplifier, a fast high voltage switch, and an oscilloscope, and [0105] optionally an imaging system (not illustrated), such as an iCCD camera or a CCD camera, if need be, to visualize the flow shape or the electric discharges in the gas channel 10.
[0106] Flow Control
[0107] The plasma microreactor 1 is adapted to handle a liquid phase and a gas phase. For both of them, it is essential for the chemistry to control the flow rates and have access to their residence times. Thus, in a preferred embodiment, the liquid 8 flow is monitored by a syringe driver (kdScientific Legato 180). Other liquid flow actuator can be used, as pressure controller or a peristaltic pump. Mass flow rate controllers (Bronkhorst EL-FLOW) can be used to control the gas flow rate and realize gas mixtures. In a preferred embodiment, the gas flow rate through the gas channel 10 is higher than the liquid flow rate through the liquid microchannel 9, preferably between 5 times and 10000 times the liquid flow rate in the liquid microchannel 9, notably comprised between 50 times and 2000 times the liquid flow rate in the liquid microchannel, and preferably comprised between 80 times and 1000 times the liquid flow rate in the liquid microchannel. Therefore, it is possible to tune the residence time of the reactive species independently from the liquid flow rate in the liquid microchannel 9: the residence time of each phase is not correlated. The liquid 8 comprises at least a solvent and optionally at least a reagent. The flow rate of liquid 8 monitored by the syringe driver can be comprised in the range from 0,5 L/min to 100 L/min, notably from 1 L/min to 50 L/min and preferably from 4 L/min to 30 L/min. The gas used can be an inert gas (for example Ar, He, N.sub.2) or an active gas (O.sub.2, H.sub.2, CO.sub.2, CO, NH.sub.3, volatile hydrocarbons such as CH.sub.4) or a mixture thereof. The flow rate of gas 12 can be comprised in the range from 0.1 mL/min to 50 mL/min, notably from 0.5 mL/min to 10 mL/min.
[0108] Electrodes
[0109] The plasma microreactor 1 according to the invention comprises at least one ground electrode 4 and at least a high voltage electrode 5.
[0110] By ground electrode (also called earth electrode) is meant an electrode which is connected to the ground.
[0111] By high voltage electrode is meant an electrode which is connected to a high voltage source 6, the high-voltage source 6 being advantageously a source of high voltage between 250 V and 30 kV, notably between 1 kV and 20 kV, preferably between 1 kV and 10 kV.
[0112] The ground electrode(s) 4 and the high-voltage electrode(s) 5 are made with an electrical conductor material, such as indium (In), tin (Sn), copper (Cu), gold (Au), oxides and/or alloys thereof or mixtures thereof, in particular indium tin oxide (ITO), copper (Cu), gold (Au), chromium (Cr) or indium-tin alloy (In-Sn) or mixture thereof, more particularly ITO optionally in mixture with gold. The ground electrode(s) and the high-voltage electrode(s) can be made with an identical or different electrical conductor material.
[0113] The ground electrode(s) can be constituted with one or several ground electrode(s). Each ground electrode can have various forms, and extend over various parts of the fluid channel 2.
[0114] In the same way, the high-voltage electrode(s) can be constituted with one or several high-voltage electrode(s), extending over various parts of the fluid channel 2. The ground electrode(s) 4 and the high voltage electrode(s) 5 can have identical or different patterns. Therefore, as the electrode arrangement defines precisely where the plasma occurs in the gas channel 10, a chemical reaction can be initiated in a part of the fluid channel 2 surrounded by the ground electrode 4 and the high voltage electrode 5, and can occur in the other part of the fluid channel 2. Particular spatial pattern of the electrode 4,5 can therefore also be useful to alternate parts of the fluid channel 2 wherein the plasma can occur and other parts wherein reactive species created in the plasma can diffuse and react the liquid phase.
[0115] The design of a specific mask layer can also be drawn (not illustrated), corresponding to the ground electrode 4 or to the high voltage electrode 5, before the manufacture of the electrode. This mask can define for example a rectangular area adapted to cover the part of the gas channel 10 where a plasma discharge occurs. Therefore, uncontrolled discharge upstream or downstream is avoided, and a repeatable discharge volume in all the reactors is allowed.
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[0117] In a preferred embodiment, the high voltage electrode 5 and the ground electrode 4 are respectively deposited on opposite faces of the support 3, for example over and under the support 3. In another preferred embodiment, at least one of the ground electrode 4 and the high voltage electrode 5 can be embedded in the support 3. In all the embodiment of the invention, at least one of the ground electrode 4 and the high voltage electrode 5 is separated from the fluidic channel 2 by a dielectric material.
[0118] In a preferred embodiment, the distance between the high-voltage electrode(s) 5 and the ground electrode(s) 4 is comprised between 10 m and 10 mm, notably between 50 m and 5 mm and preferably between 500 m and 2 mm. Smaller distances are preferred, notably between 500 m and 1000 m, in order to have a low breakdown voltage which is less energy-consuming. This distance depends also on the height of the gas channel 10, which is present between the ground electrode 4 and the high voltage electrode 5.
[0119] In reference to
[0120] In reference to
[0121] Electrical Connections
[0122] The high voltage electrode 5 and the ground electrode 4 are respectively connected to a high voltage source 6 and to the ground. In preferred embodiments, the high voltage source 6 can provide sinusoidal waves of potential or a pulsed potential.
[0123] Sinusoidal waves are generated by a function generator and magnified by a signal amplifier (Trek, 20/20C) to several thousands of volts, optionally in the range from 500 V peak to peak to 20 000 V peak to peak, preferably in the range from 1 000 V peak to peak to 10 000 V peak to peak. The frequency of a wave can vary from 50 Hz to 5 kHz. This range can be limited by the slew rate of the amplifier and/or by the behavior of the discharge in the plasma microreactor 1 (transport of species, diffusion, kinetics of the targeted chemical reactions, etc.).
[0124] High voltage pulses are produced by a pulsed generator, made of a DC high voltage generator (Spellman UM Series) coupled with a fast high voltage switch (Behlke HTS Series). It produces 100 ns-wide pulses of up to 10 kV.
[0125] Manufacture of the Plasma Microreactor
[0126] In reference to
[0127] In reference to
[0128] In reference to
[0129] In reference to
[0130] In reference to
[0131] In reference to
[0132] In reference to
[0133]
[0134] In reference to
[0135] In reference to
[0136] In reference to
[0137] In reference to
[0138] In reference to
[0139] Referring to
[0140]
[0141] Referring to
[0142] Referring to
[0143] The liquid is driven between the glass of the first coverslip 122 and the PDMS mold 103 by capillary forces until it fills completely the open parts of the microstructure. During that steps, the array of circular shapes seen on the masks 105, illustrated in
[0144] Referring to
[0145] Referring to
[0146] Referring to
[0147] Referring to
[0148] An optical diagnostic can be performed with an optical transmission imaging setup by using a transparent ITO ground electrode 4 and a transparent ITO high voltage electrode 5. In another embodiment, the ground electrode 4 can be made in an opaque material, for example in Cr/Au. Imaging the light emitted by a plasma discharge is therefore possible using one transparent electrode. If none of these diagnostics are required, both electrodes can be made out of regular, cheap and/or opaque metals.
[0149] Power Assessment
[0150] In reference to
[0151] In the absence of any plasma discharge, the plasma microreactor 1 acts as a capacitance. Therefore, the measured voltages are in phase because the equivalent electrical circuit is equivalent to two capacitances in series. This behavior is measured by a straight line displayed by the oscilloscope in XY mode.
[0152] When plasma discharges occur, small amounts of charges come across the plasma in the gas channel 10 and are deposited on the capacitance. This deviation from the pure capacitive behavior of the reactor proves the presence of discharges and can be measured when the oscilloscope displays a parallelogram-shaped XY image.
[0153] Moreover, since the voltage drop across the capacitance is proportional to its charge, the area of the parallelogram readily gives us the energy transferred to the reactor during one period, as illustrated in
[0154] In another embodiment, the electrodes 4,5 can be polarized by a pulsed high voltage. A high voltage probe (Keysight 10076 C voltage probe, 4 kV, 500 MHz or LeCroy PPE 20 kV, 1000:1, 100 MHz) provides with the voltage drop across the plasma microreactor 1 while a current probe (Pearson current probe, model 2877, 200 MHz) placed between the micro-reactor and the ground gives the total electrical current (capacitive+discharge) flowing through the plasma microreactor 1. The capacitive current being the derivative of the voltage, the discharge current can be extracted from the total current and the energy deposited into the plasma microreactor 1 can be calculated.
[0155] Optical Detection
[0156] A charge-coupled device (CCD) camera (Pixelink PL-B781U) can be mounted on a macroscope (Leica Z16 APO) and image the fluid flow inside the plasma microreactor 1. The plasma microreactor 1 can be back-illuminated by a diffuse LED lamp. Therefore, the stability of the collinear gas/liquid flow can be evaluated and the liquid 8 and gas 12 flow rates can be tuned.
[0157]
[0158]
[0159] In reference to
[0160] Plasma Enhanced Chemical Synthesis
[0161] The above described plasma microreactor 1 is adapted to generate a plasma in contact with a fluid phase. A method for generating a plasma in a plasma microreactor (1), comprises the steps of: [0162] (a) providing the plasma microreactor 1, [0163] (b) providing a liquid 8 and making the liquid flow through the liquid microchannel(s) 9 in a given direction, [0164] (c) providing a gas 12 and making the gas flow through the gas channel 10 in said direction, [0165] (d) applying a high voltage between the high voltage electrode(s) 5 and the ground electrode(s) 4 so as to generate a plasma in the gas channel 10. As the control of the liquid flow and the gas flow are independent, it is possible to tune the residence time of the liquid phase and of the gas phase, and for example having different a liquid flow rate and a different gas flow rate.
EXAMPLES
Example 1
[0166] Stabilization of the Flows
[0167]
[0168] More generally, the behaviors of cyclohexane and water flows are dependent on the respective affinities of cyclohexane and water for glass and NOA. Whereas cyclohexane has a similar affinity for glass (contact angle) 10 and NOA (contact angle) 6 which are the two materials of the fluid channel 2 walls, water only barely wets NOA (contact angle with water) 65. These contact angles were measured with a drop shape analyzer (Kriiss analyzer). The wettability of the plasma microreactor 1 material has to be taken in consideration when designing the plasma microreactor 1 for chemical reaction comprising a predefined liquid phase.
Example 2
[0169] Oxidation of Cyclohexane
[0170] Liquid cyclohexane (VWR, HiPerSolv CHROMANORM for HPLC) was introduced at three different flow rates (6 L/min, 12 L/min and 24 L/min) in the plasma microreactor 1 together with pure O.sub.2 gas at respectively 0.5 mL/min, 1.5 mL/min and 2 mL/min (sccm). A high voltage, a 2 kHz sine wave potential triggers atmospheric pressure dielectric barrier discharges in the gas channel 10. The amplitude of the potential was adapted to get a constant power of 500 mW, as measured thanks to the aforementioned electrical setup, and was controlled to be measured being between 6 kV and 7 kV peak to peak.
[0171] The outflowing mixture of liquid 8 and gas 12 was led together though a PTFE tube into a vial immersed in an 8 C. water bath. A second tube connected to the vial served as an exit for the gas 12. The cold bath reduces the stripping of the volatile cyclohexane, which affects the assessment of final conversion. Experiments with known amounts of pure cyclohexane flowing at 6 L/min and argon gas at 1mL/min in the same recovering conditions indeed showed a loss of 145% of cyclohexane, whereas a loss of sensibly 30% cyclohexane was measured without the cold bath. The temperature of 8 C. was chosen to be slightly above the melting temperature of cyclohexane (T.sub.m=6.47 C.). Indeed, when a 0 C. ice bath is used, the liquid flowing out of the tube inside the vial freezes and clogs the end of the tube. Without this temperature control, pressure rises inside the plasma microreactor 1, owing to the inflowing gas rate until the stress limits of the reactor which then debonds itself, leaks and is definitely unusable.
[0172] The analysis of the liquid 8 was performed by GC-MS/FID (Agilent, 7890B GC+5977B MSD). The chromatographs showed three main products, one secondary product and a lot of traces. Two of the main products were positively identified as cyclohexanol and cyclohexanone, and the secondary product as being cyclohexene. The third major product was thought to be cyclohexyl hydroperoxide, which was indirectly proven by two elements. Firstly, band test of the hydroperoxide function was carried out on the cyclohexane before and after passing through the plasma microreactor 1, and gave positive result only in the latter case. Secondly, NaBH4 reduction of the outflowing liquid has been carried out, and the comparison of the corresponding chromatographs showed a disappearance of the unknown peak, while the cyclohexanol peak was increased. This is coherent with the reduction of cyclohexyl hydroperoxide into cyclohexanol.
[0173] The three products cyclohexanol, cyclohexanone and cyclohexyl hydroperoxide actually stem from the same reaction chain and can be easily turned into one product (cyclohexanol, by reduction). The products are usable for industrial purposes. The mixture cyclohexanol/cyclohexanone is indeed known as KA oil and used as precursor of nylon. Therefore, it was chosen to count these products together when calculating the selectivity of the reaction.
[0174]
[0175] Table 1 illustrates the selectivity of the conversion and the proportion of converted cyclohexane (total conversion) for three different reaction times in the plasma microreactor 1.
TABLE-US-00001 TABLE 1 Reaction time Selectivity Total conversion 30 sec 71% 7% 1 min 81% 14% 2 min 67% 32%
Example 3
[0176] Variation of the Reactants
[0177] Other gases 12 can be used to perform a chemical reaction as described in the example 2. The use of pure hydrogen gas 12 on cyclohexane in the plasma microreactor 1 produces cyclohexene as the main product, which is unexpected since it proves a dehydrogenation reaction. Cyclohexene selectivity varies from 17% to 35%, decreasing with the increasing overall conversion. A significant amount of the by-products is thought to stem from the overreaction of cyclohexene which, owing to its double bond, is more reactive than cyclohexane. Table 2 illustrates possible reactions to be performed in the plasma microreactor 1 according to the provided type of gas.
TABLE-US-00002 TABLE 2 Type of gas Possible reactions Ar/He Bond breaking (not selective) Enhancing the reactivity of active gases (by helping energy transfers) O.sub.2 Partial oxidation Total oxidation H.sub.2 Hydrogenation Dehydrogenation NH.sub.3 Amination N.sub.2 Bond breaking (not selective) Amination (with H.sub.2) CO/CO.sub.2 Carbonylation
Example 4
[0178] Variation of the Design of the Liquid and Gas Microchannels
[0179] A microreactor was manufactured in Borofloat 33 glass according to the geometry depicted on
[0180]
[0181] Although the groove-like structure of the channel remains unseen with this setup, one can clearly see the difference between two areas: the centre of the channel and its edge (brighter, only on
[0182] Two comb-shaped copper electrodes were then deposited on both sides of the chip to allow direct optical visualisation. A plasma was triggered by a 2 kHz 20 kV peak-to-peak sine high voltage between these electrodes.
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REFERENCES
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