POLYGONAL CONTINUOUS FLOW REACTOR FOR PHOTOCHEMICAL PROCESSES

Abstract

The invention provides a photoreactor assembly (1) comprising a reactor (30), wherein the reactor (30) is configured for hosting a fluid (100) to be treated with light source radiation (11) selected from one or more of UV radiation, visible radiation, and IR radiation, wherein the reactor (30) comprises a reactor wall (35) which is transmissive for the light source radiation (11), wherein: (i) the reactor (30) is a tubular reactor (130), and wherein the reactor wall (35) defines the tubular reactor (130); (ii) the tubular reactor (130) is configured in a tubular arrangement (1130); (iii) the photoreactor assembly (1) further comprises a light source arrangement (1010) comprising a plurality of light sources (10) configured to generate the light source radiation (11), wherein the reactor wall (35) is configured in a radiation receiving relationship with the plurality of light sources (10); and (iv) one or more of the tubular arrangement (1130) and the light source arrangement (1010) defines a polygon (50).

Claims

1. A photoreactor assembly comprising a reactor, wherein the reactor is configured for hosting a fluid to be treated with light source radiation selected from one or more of UV radiation, visible radiation, and IR radiation, wherein the reactor comprises a reactor wall which is transmissive for the light source radiation, wherein: the reactor is a tubular reactor, and wherein the reactor wall defines the tubular reactor; the tubular reactor is configured in a coiled tubular arrangement; the photoreactor assembly further comprises a light source arrangement comprising a plurality of light sources configured to generate the light source radiation, wherein the reactor wall is configured in a radiation receiving relationship with the plurality of light sources; and wherein the coiled tubular arrangement and the light source arrangement both define polygons having mutually parallel configured polygon sides; wherein the plurality of light sources comprise Chips-on-Board light sources (COB) and/or an array of Light emitting diodes (LEDs).

2. The photoreactor arrangement according to claim 1, wherein the tubular reactor is helically coiled.

3. (canceled)

4. The photoreactor assembly according to claim 1, wherein the coiled tubular arrangement and the light source arrangement both define polygons having mutually parallel configured polygon sides, and wherein the polygons each comprise 4-10 polygon sides.

5. The photoreactor assembly according to claim 1, wherein at least a first subset of the plurality of light sources enclose the coiled tubular arrangement.

6. The photoreactor assembly according to claim 1, wherein at least a second subset of the plurality of light sources are enclosed by the coiled tubular arrangement.

7. The photoreactor assembly according to claim 1, wherein the photoreactor assembly comprises one or more cooling elements, wherein the one or more cooling elements comprise one or more of (i) one or more fluid transport channels and (ii) one or more thermally conductive elements, wherein the one or more cooling elements are in conductive thermal contact with one or more of (a) the reactor and (b) one or more of the light sources.

8. The photoreactor assembly according to claim 1, further comprising a reactor support element configured to support the reactor, wherein the reactor support element comprises a support body, wherein the support body is rotational symmetrical, wherein at least part of the tubular reactor is configured in conductive thermal contact with the support body and wherein one or more thermally conductive elements are comprised by the support body or are in conductive thermal contact with the support body.

9. The photoreactor assembly according to claim 1, wherein the photoreactor assembly comprises a number of light source elements; wherein each light source element comprises one or more of the plurality of light sources, wherein each of the light source elements comprises at least one thermally conductive element configured in conductive thermal contact with the light source, wherein the light source element comprises a reflective element at a surface of the light source element facing the reactor wall, wherein the reflective element is reflective for the light source radiation, wherein the tubular reactor and the light source elements define one or more fluid transport channels between the tubular reactor and the light source elements, wherein a minimal distance between the tubular reactor and the light source elements defines a fluid transport channel width (d), wherein the fluid transport channel width (d) is selected from the range of 1-5 mm.

10. The photoreactor assembly according to claim 9, wherein the photoreactor assembly further comprises light source element receiving elements, wherein the light source element receiving elements are configured to removably house the light source elements.

11. The photoreactor assembly according to claim 1, wherein the photoreactor assembly further comprises a wall enclosing the tubular reactor and the light source elements, wherein the wall has a reflective surface facing the tubular reactor, wherein the reflective surface is reflective for the light source radiation.

12. The photoreactor assembly according to claim 1, wherein the photoreactor assembly comprises the one or more cooling elements, wherein the photoreactor assembly further comprises a cooling system configured for transporting a cooling fluid through and/or along one or more of the one or more cooling elements, wherein (i) the cooling system comprises an air transporting device and/or (ii) the cooling system comprises a pump configured to pump a liquid.

13. (canceled)

14. A method for treating a fluid with light source radiation, wherein the method comprises: providing the photoreactor assembly according to any claim 1; providing the fluid to be treated with the light source radiation in the reactor; and irradiating the fluid with the light source radiation.

15. The method according to claim 14, comprising transporting the fluid through the reactor while irradiating the fluid with the light source radiation, and transporting a cooling fluid through and/or along one or more cooling elements.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0086] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which:

[0087] FIGS. 1A-2B depict some embodiments of the photoreactor assembly;

[0088] FIGS. 3A, 3B and 4 depicts some further aspects of the photoreactor assembly;

[0089] FIG. 5 depicts aspects of the cooling system; and

[0090] FIG. 6 depicts further aspects of the photoreactor assembly.

[0091] The schematic drawings are not necessarily to scale.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0092] FIGS. 1A and 1B schematically depict embodiments of the photoreactor assembly 1. The photoreactor assembly 1 comprises a reactor 30 for hosting a fluid 100 to be treated with light source radiation 11. The light source radiation 11 may especially be selected from the group of UV radiation, visible radiation, and IR radiation. The light sources 10 may in embodiments comprise Chips-on-Board light sources (COB) and/or an array of Light emitting diodes (LEDs). The reactor 30 comprises a reactor wall 35 which is at least partly transmissive for the light source radiation 11. The reactor wall 35 may define the reactor 30. In the depicted embodiment the reactor 30 comprises a tubular reactor 130, especially configured in a tubular arrangement 1130.

[0093] In the embodiment the tubular arrangement 1130 is pictured as a coiled tubular arrangement 1131 (see also FIG. 2 showing a top view of a tubular reactor 130 configured in a coiled tubular arrangement 1131). The coiled tubular arrangement 1131 is schematically depicted by the seven windings 36 or turns 36 of the tubular reactor 130 (the turns 36 continue from the left hand side to the right hand side). FIG. 1 further illustrate that the tubular reactor 130 is helically coiled.

[0094] The photoreactor assembly 1 further comprises a light source arrangement 1010 comprising a plurality of light sources 10 for generating the light source radiation 11. The reactor wall 35 is especially configured in a radiation receiving relationship with the plurality of light sources 10.

[0095] Especially, one or more of the tubular arrangement 1130 and the light source arrangement 1010 defines a polygon 50. This is further depicted in FIGS. 2A and 2B, wherein in the embodiment of FIG. 2A, the light source arrangement 1010 defines the polygon 50, especially a hexagon, and in the embodiment of FIG. 2B, both the light source arrangement 1010 and the tubular arrangement 1130 define the polygon 50. The embodiment of FIG. 2B is an example of an embodiment wherein the tubular arrangement 1130 and the light source arrangement 1010 both define polygons 50 having mutually parallel configured polygon edges 59. The polygons 50 are hexagons and each polygon 50 comprises six polygon edges 59.

[0096] In the embodiment depicted in FIG. 1A, (all of) the plurality of light sources 10 enclose the tubular arrangement 1130. In the embodiment depicted in FIG. 1B (all of) the plurality of light sources 10 are enclosed by the tubular arrangement 1130. Yet, in other embodiments, a first subset of the plurality of light sources 10 encloses the tubular arrangement 1130 and a second subset of the plurality of light sources 10 is enclosed by the tubular arrangement 1130. This is very schematically depicted in FIG. 3B, although the light sources 10 are not shown in the figure. Yet the light source radiation 11 is indicated.

[0097] The embodiments depicted in FIGS. 1 and 2 further comprise a reactor support element 40 to support the reactor 30. The reactor support element 40 comprises a support body 45, which is for the four depicted embodiments rotational symmetrical (around the tubular reactor arrangement axis A1. In the embodiments part of the tubular reactor 130 contacts the support body 45 and is in thermal contact with the support body 45. Such configuration may facilitate dissipation of heat from the tubular reactor 130 to the support body 45, especially if the support body 45 comprises a thermally conductive element 2 or is thermally connected to such thermally conductive elements 2. The thermally conductive element 2 may comprise a heat sink, optionally comprising fins. Such heat sinks (thermally conductive elements 2) are e.g. schematically indicated in FIG. 2 in thermal contact with the light sources 10.

[0098] FIGS. 1 and 2, further depict that the tubular arrangement axis A1 and the tube axis A2 are configured almost perpendicular to each other.

[0099] In FIGS. 3A and 3B, some further aspects of embodiments of the assembly 1 are depicted. The figures schematically depict the photoreactor assembly 1 comprising a number of light source elements 19. In FIG. 3A the photoreactor assembly 1 comprises six light source elements 19. In FIG. 3B the photoreactor assembly 1 comprises twelve light source elements 19. Each light source element 19 comprises one or more light sources 10. The light source element 19 may further comprise at least one thermally conductive element 2 configured in thermal contact with the light source 10 (as is depicted in e.g. FIG. 2B). The light source element 19 may further comprise a reflective element 1011 (reflective for the light source radiation 11) at a surface 190 of the light source element 19 facing the reactor wall 35.

[0100] In the embodiment in FIG. 3A, the light sources 10 are enclosed by the tubular arrangement 1130. In the figure, the light sources 10 are not shown, yet may be understood from the arrows depicting the light source radiation 11. To prevent light source radiation 11 from escaping from the photoreactor assembly 1, the embodiment of FIG. 3A (also) comprises a wall 4 with a reflective element 1011, especially a reflective surface 5 (facing the tubular reactor 130) enclosing the tubular reactor 130 and the light sources 10. The reflective element 1011/reflective surface 5 is especially reflective for the light source radiation 11. The reflective element 1010/surface 5 may reflect back any radiation that is not absorbed by the fluid. This may further provide an improved light homogeneity over the fluid 100. In the embodiment of FIG. 3B, the first subset of the of light sources 10 (as indicated by the arrows depicting light source light 11) enclose the tubular arrangement 1130 and the second subset of the light sources 10 are enclosed by the tubular arrangement 1130. In the embodiment, the first subset of the plurality of light sources 10 define an outer light source polygon 50,55 and the second subset of the plurality of light sources 10 define an inner light source polygon 50,54. The tubular arrangement 1130 defines yet a further polygon 50,51. Also in this embodiment, the tubular arrangement 1130 and the light source arrangement 1010 (comprising the two subsets of light sources 10) both define polygons 50, 51, 54, 55 having mutually parallel configured polygon edges 59.

[0101] The photoreactor assembly 1 may especially comprise one or more cooling elements 95, e.g., comprising one or more fluid transport channels 7 and/or one or more thermally conductive elements 2. In FIG. 3A and FIG. 3B, fluid transport channels 7 between the tubular reactor 130 and the light source elements 19 are defined by the tubular reactor 130 and the light source elements 19. Furthermore, between the wall 4 and the tubular reactor 130 (also) a fluid transport channel 7 may be defined. Comparable fluid transport channels 7 are depicted in the embodiments of FIGS. 1 and 2. The fluid transport channel may have a width d, e.g. in the range of 1-5 mm. Yet, in embodiments, see e.g. FIG. 2A wherein a (straight) fluid transport channel 7 is (also) configured, especially as a through opening, in the support body 45, the width d may be larger than 5 cm. In further embodiments, fluid channels 7 may be defined in any of the thermally conductive elements 2, especially having a width d that may be smaller than 5 cm, and e.g. larger than 0.5 cm. For instance in embodiments, a fluid transport channel 7 may be defined in the support body 45 starting at a first side of the body and ending at the same side of the body 45. The fluid transport channels 7 may be used for cooling. In FIGS. 1-3, the channels 7 are all in thermal contact with the reactor 30 while most of them are also in thermal contact with the light sources 10.

[0102] Hence, the reactor support element 40, especially the support body 45, may especially be solid or hollow, especially comprising a cavity and/or a fluid transport channel 7. The reactor support element 40, especially the support body 45, may further comprise a heatsink, especially comprising fins. In embodiments, the reactor support element 40, especially the support body 45, is finned. The reactor support element 40, especially the support body 45, may thus be configured for facilitating a flow of a cooling fluid 91 (e.g. air 91,92 and/or water 91,93 or another cooling liquid 91,93) through and/or along the reactor support element 40.

[0103] Elements of the cooling system 90 are further depicted in FIG. 5. The cooling system may comprise the cooling elements 95. The cooling system 90 is especially configured for transporting the cooling fluid 91 through and/or along one or more of the one or more cooling elements 95 (especially fluid transport channels 7 and/or thermally conductive elements 2). The cooling system may e.g. comprise an air transporting device 95 for transporting a gaseous fluid 91,92, especially air 91,92 through one or more of the fluid transport channels 7 and along one or more the thermally conductive elements 2. Additionally or alternatively a liquid (cooling) fluid, 91, 93 may be used, and the cooling system may comprise a pump for transporting the liquid cooling fluid 91,93. In the embodiments of FIG. 5, for instance, the photoreactor assembly 1 comprises air transport devices 95, such as fans, configured for transporting air along thermally conductive elements 2 in thermal connection with the light sources 10, such as heat sinks of the light source element 19. Further a pump may be arranged to pump a liquid cooling fluid 91,93 through e.g. some of the fluid transport channels 7. In the embodiment also air 91,92 is transported through one or more of the fluid transport channels 7 via a fan 90,95 arranged at the top of the photoreactor assembly 1.

[0104] The light source elements 19 are in embodiments removably housed in the photoreactor assembly 1. The photoreactor assembly 1 may e.g. comprise light source element receiving elements 80 configured for removably housing the light source elements 19, as is very schematically depicted in FIG. 4. In embodiments, every single light source element 19 may be removed separately. Yet, in further embodiments, (at least part of) the light source elements 19 together form a light source unit, and the light source unit(s) may be removably housed in the light source element receiving elements 80. The light source element receiving elements 80 may therefore also define a light source unit receiving unit (for removably housing the light source unit).

[0105] In FIG. 6, aspects of a further embodiment of the photoreactor assembly 1 are depicted. In this embodiment, the reactor wall 35 of the tubular reactor 130 actually comprises an inner reactor wall 351 and an outer reactor wall 352 together defining the tubular reactor 130. Hence, in embodiments, the tube 32 may (also) have an inner wall 351 and an outer wall 352. Herein, such configuration is also called a double walled tube 32. Depending on the configuration of the light source arrangement 1010 (not depicted in the figure) the inner reactor wall 351, the outer reactor wall 352 or both walls 351, 352 are configured at least partly transmissive for the light source radiation 11. In this embodiment, the tubular arrangement define the polygon 50 (a square). In the embodiment, the fluid 100 may flow in the channel configured between the inner wall 351 and the outer wall 352. Herein such channel is also referred to as (square) annulus 137. As an alternative of the depicted embodiment, the tubular reactor 130 may also be defined by a plurality parallel tubes 32, together defining the reactor 30 (not depicted). The tube axis A2 of the plurality of tubes 32 (as well as the tube axis of the double walled tube 32) may especially also be configured parallel to the tubular arrangement axis A1. Yet, in embodiments, the plurality of tubes 32 in such embodiment may be configured at an angle with respect to the tubular arrangement axis A1. Such angle is especially an acute angle. Herein, the tubular arrangement 1130 of the double walled tube 32 or the (alternative) one described above comprising the plurality of tubes 32 is also named a straight tubular arrangement 1132.

[0106] The photoreactor assembly 1 described herein may be used for treating the fluid 100 with light source radiation 11. During use, the fluid 100 is provided in the reactor 30 and irradiated with the light source radiation 11. The method may comprise a batch process. Yet, the method may especially comprise a continuous process. During the continuous process, the fluid 100 is transported through the reactor 30 while irradiating the fluid 100 with the light source radiation 11. Simultaneously a cooling fluid 91 may be transported through and/or along one or more cooling elements 95 as is schematically depicted in FIG. 5.

[0107] Hence, the invention provides embodiments of a reactor 30 with light sources 10 that can easily be replaced (for instance when a certain reaction needs a specific wavelength region), and may have a very high efficiency, both in terms of light/radiation output versus power input of the source, and in capturing of the radiation by the reactants. In embodiments, the assembly 1 comprises a hexagonal enclosure formed by six or eight light source elements 19 comprising a heatsink 2, each carrying one or more COBs. The heatsinks 2 may especially facilitate cooling of the light sources 10 and maintaining the COB 10 at a low temperature (for maximum efficiency).

[0108] In embodiments, a COB 10 (with or without phosphor) and/or an array of LEDs 10 (not necessarily of the same type) is configured on a heatsink 2 that is big enough to keep the COB 10 or LEDs 10 at a low temperature. For instance, three to ten of such heatsinks 2 (configured as light source elements 19) are slit into a frame 80 in such a way that they form a polygonal structure 50/enclosure. The fluid 100 containing (photosensitive) reactants may be flown through a tiny tube 32 that is coiled around a core comprising a body support 45 with the same polygonal shape 50 (in embodiments with rounded edges to prevent damaging of the tube 32 while coiling, taking the minimum bending radius of the tube into account, depending on the tube diameter). The core 45 and tube 32 may in embodiments be placed in the enclosure from top or bottom side. The coiled tube 32 especially extends over the whole height of the enclosure, so all radiation 11 radiated by the sources 10 may imping on the coiled tube 32, and especially no light source radiation 11 will escape from top or bottom, or imping on other parts of the enclosure.

[0109] Optical simulations have shown that with a hexagonal core 45 and a hexagonal light source arrangement 1010 the efficiency is increased by 10% compared to a hexagonal light source arrangement 1010 and a round core 45 with a diameter equal to the smallest size of the hexagon 50. The efficiency may especially be improved when the core 45 has the same polygonal shape 50 as the enclosure. The efficiency increase gradually declines with increasing number of edges 59 of the polygonal shape 50 and is a few percent or less for eight or more edges 59. The efficiency may in embodiments further may be increased by minimizing a distance between the tubular arrangement 1130 and the light source arrangement 1010. The heatsinks 2,19 with the LEDs 10 can be replaced easily, for instance to change the wavelength region.

[0110] The tubular reactor may be configured in a tubular arrangement. For example, the tubular arrangement may comprise a coiled tubular arrangement, wherein the tubular reactor is helically coiled. Another example is that the tubular reactor may comprise an inner reactor wall and an outer reactor wall, together defining the tubular reactor, wherein one or more of the inner reactor wall and the outer reactor wall is transmissive for the light source radiation, and wherein the tubular arrangement comprises a straight tubular arrangement.

[0111] In the embodiments described above, the expression “thermal contact” may (mainly) relate conduction and/or convection. The expression “thermal contact” may relate to direct thermal contact and/or indirect thermal contact. Preferably, the thermal contact is at least or mainly via conduction as it provides optimal thermal management i.e. cooling.

[0112] Preferably, the thermal contact is direct thermal contact.

[0113] The term “plurality” refers to two or more.

[0114] The terms “substantially” or “essentially” herein, and similar terms, will be understood by the person skilled in the art. The terms “substantially” or “essentially” may also include embodiments with “entirely”, “completely”, “all”, etc. Hence, in embodiments the adjective substantially or essentially may also be removed. Where applicable, the term “substantially” or the term “essentially” may also relate to 90% or higher, such as 95% or higher, especially 99% or higher, even more especially 99.5% or higher, including 100%.

[0115] The term “comprise” includes also embodiments wherein the term “comprises” means “consists of”.

[0116] The term “and/or” especially relates to one or more of the items mentioned before and after “and/or”. For instance, a phrase “item 1 and/or item 2” and similar phrases may relate to one or more of item 1 and item 2. The term “comprising” may in an embodiment refer to “consisting of but may in another embodiment also refer to “containing at least the defined species and optionally one or more other species”.

[0117] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

[0118] The devices, apparatus, or systems may herein amongst others be described during operation. As will be clear to the person skilled in the art, the invention is not limited to methods of operation, or devices, apparatus, or systems in operation.

[0119] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims.

[0120] In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim.

[0121] Use of the verb “to comprise” and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.

[0122] The article “a” or “an” preceding an element does not exclude the presence of a plurality of such elements.

[0123] The invention may be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In a device claim, or an apparatus claim, or a system claim, enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

[0124] The invention also provides a control system that may control the device, apparatus, or system, or that may execute the herein described method or process. Yet further, the invention also provides a computer program product, when running on a computer which is functionally coupled to or comprised by the device, apparatus, or system, controls one or more controllable elements of such device, apparatus, or system.

[0125] The invention further applies to a device, apparatus, or system comprising one or more of the characterizing features described in the description and/or shown in the attached drawings. The invention further pertains to a method or process comprising one or more of the characterizing features described in the description and/or shown in the attached drawings.

[0126] The various aspects discussed in this patent can be combined in order to provide additional advantages. Further, the person skilled in the art will understand that embodiments can be combined, and that also more than two embodiments can be combined. Furthermore, some of the features can form the basis for one or more divisional applications.