MODULAR OSCILLATORY FLOW PLATE REACTOR

Abstract

The present application relates to an improved apparatus for mixing intensification in multiphase systems, which can be operating in continuous or batch mode. In particular, it relates to a reactor, which can be assembled and disassembled easily for cleaning. The apparatus is based on oscillatory flow mixing (OFM) and comprises an oscillatory flow plate reactor (OFPR) provided with 2D Smooth Periodic Constrictions (2D-SPCs). The apparatus can be fully thermostatized and it is based on a modular system, in order to achieve most of the industrial application. The OFPR is suitable for multiphase applications such as screening reactions, bioprocess, gas-liquid absorption, liquid-liquid extraction, precipitation and crystallization. Regarding its size and geometry and the ability to operate at low flow rates, reagent requirements and waste are significantly reduced, as well as the manufacturing and operating costs, compared to the common reactor, such as continuous stirred tank reactor (CSTR) and the conventional OFR.

Claims

1. An apparatus for mixing intensification comprising: a plate reactor provided with a reactor vessel provided with smooth periodic constrictions (SPC), wherein the said smooth periodic constrictions (SPC) are present in two parallels faces of the rectangular or square cross section tube, characterizing the 2D smooth periodic constrictions; a mixing chamber; and oscillation means to oscillate the liquid or multiphase fluid within the reactor vessel.

2. An apparatus according to claim 1, wherein said plate reactor is built-up by stacking two or more slices resulting in tubes with rectangular or square cross section.

3. An apparatus according to claim 1, wherein said reactor vessel is provided with smooth edges.

4. An apparatus according to claim 1, wherein said reactor vessel is provided with at least two inlets or outlets.

5. An apparatus according to claim 1, wherein said reactor plate is assemblable and disassemblable.

6. An apparatus according to claim 1, wherein said reactor vessel is in the form of single plate reactor or at least two plate reactors, displaced in parallel, by stack up the plates.

7. An apparatus according to claim 1, wherein said reactor vessel is totally thermostatized.

8. An apparatus according to claim 1, wherein the said apparatus comprises a jacket.

9. An apparatus according to claim 1, wherein the mixing chamber is provided with at least two inlet or outlet ports.

10. An apparatus according to claim 1, wherein the distance (L) between consecutive convergent sections is 1 to 5 times the tube width (Dw) of the straight section.

11. An apparatus according to claim 1, wherein the convergent-divergent section length (L1) of the reactor vessel is 0.5 to 3 times the tube width (Dw) of the straight section.

12. An apparatus according to claim 1, wherein the shortest tube width (dow) of the convergent divergent section of the reactor vessel is 0.1 to 0.5 times the tube width (Dw) of the straight section.

13. An apparatus according to claim 1, wherein the radius of curvature (Re) of the sidewall of the convergent section of the reactor vessel is 0.1 to 0.5 times the tube width (Dw) of the straight section.

14. An apparatus according to claim 1, wherein the radius of curvature (Rd) of the sidewall of the divergent section of the reactor vessel is 0.1 to 0.5 times the tube width (Dw) of the straight section.

15. An apparatus according to claim 1, wherein the radius of curvature (Rt) at the convergent-divergent section centre of the reactor vessel is 0.1 to 0.5 times the tube width (Dw) of the straight section.

16. An apparatus according to claim 1, wherein the thickness perpendicular to xOy plane (m) is 0.2 to 3 times the tube width (Dw) of the straight section.

17. An apparatus according to claim 1, wherein the open area (a) is between 10% and 50%.

18. Use of the apparatus disclosed in claim 1 in multiphase applications such as screening reactions, bioprocess, gas-liquid absorption, liquid-liquid extraction, precipitation and crystallization.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0035] For a better understanding of the technology, some figures are attached representing preferred embodiments of the present technology which, however, are not to be construed as being limiting other possible embodiments falling within the scope of protection.

[0036] FIG. 1 illustrates the state of the art of the reactor based on Smooth Periodic Constrictions used in tubes with circle cross section. In particular, FIG. 1 illustrates the following elements:

[0037] DInner diameter of the straight section;

[0038] d.sub.0Shortest diameter of the convergent-divergent section;

[0039] L.sub.1Convergent-divergent section length;

[0040] L.sub.2Straight section length;

[0041] FIG. 2 illustrates a view of the reactor, identifying the design and the parameters that characterize the present technology. In particular, FIG. 2 illustrates the following elements:

[0042] D.sub.wTube width of the straight section;

[0043] d.sub.0wShortest tube width of the convergent-divergent section;

[0044] L.sub.1Convergent-divergent section length;

[0045] L.sub.2Straight section length;

[0046] Thickness perpendicular to x0y plane.

[0047] FIG. 3 illustrates a sectional view of the reactor, identifying the design and the parameters that characterize the present technology. In particular, FIG. 3 illustrates the following elements:

[0048] 1Reactor;

[0049] 2Straight section;

[0050] 3Convergent section;

[0051] 4Divergent section;

[0052] 5Convergent-divergent section;

[0053] D.sub.wTube width of the straight section;

[0054] d.sub.0wShortest tube width of the convergent-divergent section;

[0055] LDistance between consecutive convergent sections;

[0056] L.sub.1Convergent-divergent section length;

[0057] L.sub.2Straight section length;

[0058] R.sub.cRadius of curvature of the sidewall of the convergent section;

[0059] R.sub.dRadius of curvature of the sidewall of the divergent section;

[0060] R.sub.tRadius of curvature at the convergent-divergent section centre.

[0061] FIG. 4 illustrates a plan view of the oscillatory flow reactor apparatus based on plate reactor. In particular, FIG. 4 illustrates the following elements:

[0062] 6plate reactor;

[0063] 7jacket;

[0064] 8reactor vessel based on 2D-SPC;

[0065] 9mixing chamber;

[0066] 10oscillatory unit;

[0067] 11reactor inlet;

[0068] 12jacket inlet;

[0069] 13jacket outlet;

[0070] 14inlet or outlet;

[0071] 15reactor exit.

[0072] D.sub.wtube width of the straight section;

[0073] d.sub.0wShortest tube width of the convergent-divergent section;

[0074] L.sub.1Convergent-divergent section length;

[0075] L.sub.2Straight section length.

DESCRIPTION OF EMBODIMENTS

[0076] The present technology will now be described with reference to the accompanying figures, which however are not to be construed as being limiting other possible embodiments falling within the scope of protection.

[0077] The present application relates to an apparatus for mixing based on oscillatory flow plate reactors provided with 2D smooth periodic constrictions. The present technology comprises dimensions ranges that characterize the reactor vessel provided with 2D smooth periodic constrictions (FIGS. 2 and 3), here defined as convergent-divergent section (5), and its arrangement in plates, as illustrated on FIG. 4.

[0078] In one embodiment, the said apparatus comprises a plate reactor provided with a reactor vessel (8) provided with smooth periodic constrictions (SPC), wherein the said smooth periodic constrictions (SPC) are present in two parallels faces of the rectangular or square cross section tube, characterizing the 2D smooth periodic constrictions; a mixing chamber (9); and oscillation means to oscillate the liquid or multiphase fluid within the reactor vessel.

[0079] The reactor vessel (8) may be made of metal, plastic, glass or any porous material. The reactor vessel (8) is characterized by a bundle of reactors (1), as illustrated on FIGS. 2 and 3, that have alternatively straight sections (2) and convergent-divergent sections (5). Each convergent-divergent section (5) consists of a convergent section (3) and a divergent section (4). The convergent section (3) gradually reduces its tube width, and the divergent section (4) presents a gradually increasing the tube width. The shortest tube width, obtained at the junction of convergent section (3) and divergent section (4), is defined as d.sub.0w. The tube width (D.sub.w) of the straight section (2) is larger than d.sub.0w. The convergent and divergent sections have a curved sidewall defined by the radius of curvature (R.sub.c) of the sidewall of the convergent section (3), the radius of curvature (R.sub.d) of the sidewall of the divergent section (4) and the radius of curvature (R.sub.t) at the convergent-divergent section (5) centre.

[0080] In order to obtain the best mixing condition, the reactor (1) shall fulfil the following conditions: [0081] 1. The distance (L) between consecutive convergent sections (3) is 1 to 5 times the tube width (D.sub.w) of the straight section (2). That is L=1-5D.sub.w; [0082] 2. The convergent-divergent section (5) length (L.sub.1) is 0.5 to 3 times the tube width (D.sub.w) of the straight section (2). That is L.sub.1=0.5-3D.sub.w; [0083] 3. The shortest width (d.sub.0w) of the convergent-divergent section (5) is 0.1 to 0.5 times the tube width (D.sub.w) of the straight section (2). That is d.sub.0w=0.1-0.5D.sub.w; [0084] 4. The radius of curvature (R.sub.c) of the sidewall of the convergent section (3) is 0.1 to 0.5 times the tube width (D.sub.w) of the straight section (2). That is R.sub.c=0.1-0.5D.sub.w; [0085] 5. The radius of curvature (R.sub.d) of the sidewall of the divergent section (4) is 0.1 to 0.5 times the tube width (D.sub.w) of the straight section (2). That is R.sub.d=0.1-0.5D.sub.w; [0086] 6. The radius of curvature (R.sub.t) at the convergent-divergent section (5) centre is 0.1 to 0.5 times the tube width (D.sub.w) of the straight section (2). That is R.sub.t=0.1-0.5D.sub.w; [0087] 7. The open area () takes the values range between 10% and 50%.

[0088] The reactor vessel (8) characterized by a bundle of reactors (1) is incorporated in a plate reactor (6), as illustrated on FIG. 4.

[0089] The plate reactor (6) comprises a continuous serpentine reactor vessel (8), characterized by a bundle of reactors (1), and an external tube used as jacket (7) for reactor vessel (8) thermostatization, or mass transfer, if reactor vessel (8) is made of porous material. The plate reactor (6) is build-up by stacking up at least two slices resulting in tubes with rectangular or square cross section (x0z section plane), rather than circle cross section presented in WO 2015/056156 [1], with a thickness perpendicular to x0y plane (). The edges of the reactor vessel (8) can be smoothed. The jacket (7) has an inlet (12) and an outlet (13). This reactor vessel (8) has at least two inlets or outlets (14), to allow the addition of reactants or other substances, or sample collection. The plate reactor (6) can be arranged in parallel by stacking up the plates. The plate reactors (6) are connected by U tubes. The first plate reactor (6) is connected to an oscillatory unit (10), which induces a simple harmonic motion to the fluid in the reactor vessel (8), by a mixing chamber (9) provided with at least two inlets (11).

[0090] FIG. 4 shows a plan view of the oscillatory flow reactor apparatus based on plate reactor (6), constituted by an inner tube with rectangular or square cross section (x0z section plane), here defined as reactor vessel (8), presenting a bundle of reactors (1), an external tube used as jacket (7) for reactor vessel (8) thermostatization, or mass transfer if reactor vessel (8) is made of porous material, and at least two inlets or outlets (14), to allow the addition of reactants or other substances, or sample collection.

[0091] The plate reactors (6) can be closed using a close valve at reactor exit (15).

[0092] The number, size and length of plate reactor (6) are designed according to the system specification.

[0093] The plate reactors (6) can be operated in batchwise or continuously.

[0094] The liquid or multiphase fluids are fed to the reactor vessel (8) through the inlets (11) of the mixing chamber (9).

[0095] The liquid or multiphase fluid is oscillated in the axial direction by means of oscillatory unit (10), developing an efficient mixing mechanism where fluid moves from the walls to the centre of the tube with intensity controlled by the oscillation frequency (f) and amplitude (x.sub.0). The formation and dissipation of eddies in the reactor results into significant enhancement in processes such as heat transfer, mass transfer, particle mixing and separation, beyond others.

[0096] The reactor will obtain the optimum mixing conditions when: [0097] 1. The distance (L) between consecutive convergent sections (3) is 1 to 5 times the tube width (D.sub.w) of the straight section (2), preferably 3D; [0098] 2. The convergent-divergent section (5) length (L.sub.1) is 0.5 to 3 times the tube width (D.sub.w) of the straight section (2), preferably 1.44D; [0099] 3. The shortest tube width (d.sub.0w) of the convergent-divergent section (5) is 0.1 to 0.5 times the tube width (D.sub.w) of the straight section (2), preferably 0.41D; [0100] 4. The radius of curvature (R.sub.c) of the sidewall of the convergent section (3) is 0.1 to 0.5 times the tube width (D.sub.w) of the straight section (2), preferably 0.47D; [0101] 5. The radius of curvature (R.sub.d) of the sidewall of the divergent section (4) is 0.1 to 0.5 times the tube width (D.sub.w) of the straight section (2), preferably 0.47D; [0102] 6. The radius of curvature (R.sub.t) at the convergent-divergent section (5) centre is 0.1 to 0.5 times the tube width (D.sub.w) of the straight section (2), preferably 0.32D; [0103] 7. The thickness perpendicular to x0y plane () is 0.2 to 3 times the tube width (D.sub.w) of the straight section (2), preferably 0.63D; [0104] 8. The open area (a) takes the values range between 10% and 50%, preferably, 41%; [0105] 9. The oscillation frequency of the medium is between 1 and 12 Hz; [0106] 10. The oscillation amplitude of the medium is between 0 and 0.5 times the distance (L) between consecutive convergent sections (3).

[0107] The disclosed technology can be used in mass and heat transfer intensification. In particular, the disclosed technology can be used in mixing intensification between liquid/liquid, liquid/gas and liquid/solid phases.

[0108] The disclosed technology overcomes the disadvantages of the conventional OFR, based on annular baffles, especially in what concerns the dead zones decreasing and the quick cleaning process. The disclosed technology also overcomes the disadvantages of the meso-OFR based on SPC, especially in what concerns the decrease of the secondary nucleation, agglomeration and clogging problems. The present invention fulfils the gaps identified in WO 2015/056156, especially when solids are involved, namely, solid deposition and fouling, when low oscillatory conditions need to be imposed.

[0109] The disclosed technology relates to a plate reactor, which can be assembled and disassembled easily for cleaning.

[0110] As the disclosed technology is based on a modular system, it allows a quick reactor change according to industries' needs, a distinguishing and striking characteristic of other reactors.

[0111] The disclosed technology can be operated in batchwise or continuously, this characteristic being of particular relevance in chemical, bio-chemical, biological and pharmaceutical industry.

[0112] The disclosed technology offers unique features in comparison with conventional chemical reactors. It is suitable for multiphase applications such as screening reactions, bioprocess, gas-liquid absorption, precipitation and crystallization operating in batch or continuous mode.

REFERENCES

[0113] [1] A. Ferreira, F. Rocha, J. A. Teixeira, A. Vicente, Apparatus for mixing improvement based on oscillatory flow reactors provided with smooth periodic constrictions, WO/2015/056156, 2015. [0114] [2] M. R. Mackley, R. L. Skelton, K. B. Smith, Processing of liquid/solid mixtures using pulsations, GB 2 276 559 A, 1994. [0115] [3] X. Ni, K. Murray, Y. Zhang, D. Bennett, T. Howes, Polymer product engineering utilising oscillatory baffled reactors, Powder Technol. 124 (2002) 281-286. doi:10.1016/50032-5910(02)00022-0. [0116] [4] R. K. Thakur, C. Vial, K. D. P. Nigam, E. B. Nauman, G. Djelveh, Static mixers in the process industriesa review, Chem. Eng. Res. Des. 81 (2003). [0117] [5] J. C. B. Lopes, P. Laranjeira, M. Dias, A. Martins, Network mixer and related mixing process, US 2009/0016154 A1, 2009. [0118] [6] P. E. M. S. C. Laranjeira, NETMIX Static MixerModelling, CFD simulation and Experimental Characterisation, Faculdade de Engenharia, Universidade do Porto, 2005. [0119] [7] T. McGlone, N. E. B. Briggs, C. A. Clark, C. J. Brown, J. Sefcik, A. J. Florence, Oscillatory Flow Reactors (OFRs) for Continuous Manufacturing and Crystallization, Org. Process Res. Dev. 19 (2015) 1186-1202. doi:10.1021/acs.oprd.5b00225 . [0120] [8] J. R. McDonough, a. N. Phan, a. P. Harvey, Rapid process development using oscillatory baffled mesoreactorsA state-of-the-art review, Chem. Eng. J. 265 (2015) 110-121. doi:10.1016/j.cej.2014.10.113. [0121] [9] N. M. F. Reis, Novel Oscillatory Flow Reactors for Biotechnological Applications, Minho University, 2006.

[0122] The description, of course, is in no way limited to the embodiments described in this document and any person skilled in the art may envisage many possibilities of modifying it, sticking to the disclosed concept, as defined in the claims.

[0123] The preferred embodiments described above may obviously be combined together. The following claims define additionally some preferred embodiments.