GB2514614A

GB2514614A - Chemical process apparatus and methods

Info

Publication number: GB2514614A
Application number: GB1309752.2A
Authority: GB
Inventors: Simon Johnson
Original assignee: Individual
Current assignee: Individual
Priority date: 2013-05-31
Filing date: 2013-05-31
Publication date: 2014-12-03
Also published as: GB201309752D0

Abstract

An apparatus 100 for conducting chemical process steps comprising at least two vessels 120 connected by a conduit 110 for passage of fluid between the vessels, wherein said at least two vessels comprise openings 111 to the exterior of the apparatus for introducing chemicals into the apparatus and for removing products from the apparatus and wherein the apparatus comprises electromagnetic heating means 221 for heating the contents of the at least two vessels. Preferably, the apparatus comprises a glass substrate which comprises the vessels or wells wherein each vessel is connected to at least one secondary channel 112 which links with the conduit. The heating means is ideally electromagnetic heating coils wherein a coil is associated with each well. The vessels may be positioned in series or parallel.

Description

Chemical Process Apparatus and Methods The present invention relates to apparatus comprising multiple vessels for conducting chemical process steps and methods of conducting chemical process steps using apparatus comprising multiple vessels.

In the petroleum industry, crude oil is refined by fractional distillation to provide a range of petroleum products which can be used as fuels, lubricants and chemical feedstocks. Typically the lighter distillation fractions such as liquefied petroleum gas, gasoline, naptha, kerosene and diesel are of greater commercial value, due to their widespread use as transportation fuels, compared to the heavier distillation fractions such as gas oils and residues. These heavier distillation fractions can be converted to lighter fractions through cracking processes.

For example, the commonly used fluid catalytic cracking technique is a continuous process whereby a heavy gas oil feedstock is pre-heated and brought into contact with a hot zeolite catalyst in a reactor, causing the gas oil to vaporize and breakdown into lighter petroleum products. The spent catalyst is then separated from the product mixture, regenerated by burning off carbonaceous deposits and recycled into the reactor. The lighter petroleum products are separated by fractional distillation and the remaining heavy residues recycled into the reactor or removed for further processing.

Fluid catalytic cracking of crude oil or crude oil derivatives has a high energy demand due to the high operating temperatures used.

It is an object of the present invention to provide chemical process apparatus and methods which may be improved over existing apparatus and/or methods. Preferred embodiments relate to cracking of crude oil and treatment of waste water.

According to the first aspect of the present invention there is provided an apparatus for conducting chemical process steps comprising at least two vessels connected by a conduit for passage of fluid between the vessels, wherein said at least two vessels comprise openings to the exterior of the apparatus for introducing chemicals into the apparatus and for removing products from the apparatus and wherein the apparatus comprises electromagnetic heating means for heating the contents of the at least two vessels.

The vessels are suitably adapted to receive chemicals and contain the chemicals during one or more chemical process steps. The vessels are preferably constructed from glass.

Suitable materials from which the apparatus may be constructed include glass.

Suitably the apparatus comprises more than two vessels connected by conduits for passage of fluid between the vessels. In some embodiments the apparatus comprises at least four vessels connected by conduits for passage of fluid between the vessels; it may include at least nine vessels or at least twenty-five vessels. In some embodiments the apparatus comprises up to one-thousand vessels connected by conduits for passage of fluid between the vessels, for example up to one-hundred vessels or up to forty-nine vessels. The apparatus may comprise more than one group of vessels connected by conduits. For example the apparatus may comprise a first group of at least two vessels connected by a conduit and a second group of at least two vessels connected by a conduit wherein the vessels in the first group are not connected to the vessels in the second group.

Suitably the apparatus comprises from four to one-hundred vessels connected by conduits for passage of fluid between the vessels, for example from nine to one-hundred vessels or from nine to forty-nine vessels.

Suitably the vessels have a volume of at least 0.5 cm3, preferably at least 1 cm3, for example at least 10 cm3. In some embodiments the vessels have a volume of up to 100,000 cm3, preferably up to 10,000 cm3, for example up to 1000 cm3.

Suitably the vessels have a volume of from 0.5 cm3 to 10,000 cm3, for example from 1 cm3 to 10,000 cm3 orfrom 1cm3 to 1000 cm3.

Preferably more than 50 %, more preferably more than 95 %, of the vessels have the same volume. Preferably substantially all of the vessels have the same volume.

The at least two vessels are connected by a conduit. The conduit suitably allows mass transfer between the two vessels. For example chemicals in a first vessel may be pumped from the first vessel through a conduit into a second vessel. The at least two vessels open to the exterior of the apparatus may be open to the exterior of the apparatus via conduits.

Therefore chemicals contained in a container on the exterior of the apparatus may be pumped from the container into a vessel of the apparatus through a conduit. Suitably the conduits communicate at two ends to two vessels or to a vessel and the exterior of the apparatus such that chemicals can be transferred through the conduits between the vessels or between a vessel and the exterior of the apparatus.

The apparatus comprises at least two vessels connected by a conduit. The at least two vessels connected by a conduit comprise vessels that are connected by conduits to at least one other vessel. The at least two vessels connected by a conduit may be connected in series. The at least two vessels connected by a conduit may be connected in parallel.

Suitably the apparatus comprises more than two vessels connected by conduits.

The vessels connected by conduits may comprise vessels which are connected by conduits to up to two other vessels. Such vessels may be connected in series so that mass transfer is made possible through the conduits to each of the vessels connected by conduits in a linear sequence. The apparatus may comprise more than one group of vessels connected in series.

In alternative embodiments the apparatus comprising more than two vessels connected by conduits comprises at least one vessel which is connected by conduits to at least three other vessels. Preferably the apparatus comprises more than one vessel which is connected by conduits to three other vessels.

In some embodiments the apparatus comprising more than two vessels connected by conduits comprises at least one vessel which is connected by conduits to at least four other vessels.

Preferably the apparatus comprises more than one vessel which is connected by conduits to at least four other vessels.

In some embodiments the apparatus comprises at least two vessels and at least four conduits.

The at least four conduits may be arranged in a conduit network. The conduit network comprises at least one junction between at least two conduits. A conduit network may be an arrangement of conduits which connects the exterior of the apparatus to more than two vessels. For example the conduit network may allow mass transfer between the exterior of the apparatus and at least two vessels. Suitably the apparatus comprises more than one conduit network.

The conduit network may comprise a main conduit which connects to the exterior of the apparatus, and secondary conduits which connect to the main conduit and to the at least two vessels.

In some embodiments the apparatus comprises two conduit networks which connect the exterior of the apparatus to at least two vessels. Suitably the apparatus comprises two conduit networks which connect the exterior of the apparatus to more than two vessels. Such an arrangement provides an apparatus with a group of vessels which are connected in parallel by conduits so that mass transfer between the exterior of the apparatus and the vessels so connected may occur simultaneously. The apparatus may comprise more than one group of vessels connected in parallel.

In further embodiments the apparatus comprises vessels which are connected in a combination of series and parallel arrangements. Suitably these embodiments comprise at least two groups of vessels connected in series by conduits, and two conduit networks, one conduit network connecting the exterior of the apparatus to the first vessel of each of the two groups and the other conduit network connecting the exterior of the apparatus to the final vessel of each of the two groups. Preferably the apparatus comprises such a parallel arrangement of more than two groups of vessels connected in series. The apparatus may comprise more than one parallel arrangement of at least two groups of vessels connected in series by conduits.

It will be appreciated that by varying the number of conduits and the connectivity of the conduits to the vessels, many different patterns of connectivity between vessels is possible.

In some embodiments the vessels of the apparatus comprise a catalyst. The catalyst may be suitable for carrying out a catalytic cracking process. Preferably the catalyst is a dielectric material which can be heated by an electromagnetic heating means. Suitable catalysts include catalysts which comprise nickel, catalysts which comprise cobalt, mixed-oxide catalysts comprising nickel and cobalt, and zeolites. Suitably the zeolite catalyst comprises nickel or cobalt or a mixture thereof. Suitably the catalyst is provided as a solid, for example the catalyst may be formed into a disc-shaped mass and placed in the vessels.

The apparatus is provided with electromagnetic heating means for heating the contents of the at least two vessels.

Suitable electromagnetic heating means include dielectric heating means and induction heating means.

Electromagnetic heating means may heat the contents of the vessels through dielectric heating. Dielectric heating occurs when a polar material with low electrical conductivity is exposed to an oscillating electromagnetic field of radio-frequency or microwave radiation. The applied electromagnetic field causes the polar molecules of the material to rotate into alignment with the field. Continuously alternating the applied field causes repeated molecular rotations which heat the polar material.

Dielectric heating may be used to selectively heat the catalyst in a catalytic cracking process instead of heating the catalyst and the substrate, for example crude oil, as is done in a conventional catalytic cracking process. Using dielectric heating in this way may reduce the high energy consumption of a catalytic cracking process.

Suitable electromagnetic heating means comprise an electromagnetic generator. The apparatus may comprise an electromagnetic generator. Suitable electromagnetic generators include an element. Suitable elements include elements which comprise a wire coil and elements which comprise two plate-like electrodes separated by a space. In embodiments wherein the element comprises two plate-like electrodes separated by a space, suitably an alternating electric field is applied across the two electrodes to heat material within the space.

In embodiments wherein the element comprises a wire coil, suitably an alternating electric current is applied through the wire coil to heat material within the coil.

Suitably the electromagnetic heating means comprises a wire coil and two plate-like electrodes. Preferably one or more vessels of the apparatus are positioned within the coil and between the two plate-like electrodes in order for their contents to be heated by the electromagnetic heating means.

In some embodiments the apparatus comprises one electromagnetic heating means. Suitably the contents of more than one vessel are heated by one electromagnetic heating means. For example the contents of substantially all of the vessels of the apparatus may be heated by one electromagnetic heating means.

In some embodiments the apparatus comprises more than one electromagnetic heating means. Suitably the apparatus comprises more than one electromagnetic heating means which is adapted to heat the contents of more than one vessel. In embodiments wherein the vessels of the apparatus are substantially aligned in rows, a row may be provided with an electromagnetic heating means such that the contents of more than one of the vessels in the row may be heated by one electromagnetic heating means. Suitably the contents of all of the vessels in the row are heated by one electromagnetic heating means.

In some embodiments the apparatus comprises more than one electromagnetic heating means which is adapted to heat the contents of a single vessel. For example more than one vessel may be provided with an individual electromagnetic heating means adapted to predominately heat the contents of that vessel only. Suitably at least 70 % of the vessels, preferably at least 90 % of the vessels or substantially all of the vessels are provided with an individual electromagnetic heating means. Preferably substantially all of the vessels are heated independently by individual electromagnetic heating means.

The element of an electromagnetic generator may be embedded in the apparatus such that it surrounds the vessel or vessels but is separated from the contents of the vessel or vessels.

The element of an electromagnetic generator may be arranged inside more than one vessel.

Preferably the element is arranged inside more than one vessel.

The element of an electromagnetic generator arranged inside a vessel may have a size and shape complimentary to the size and shape of the vessel. The element may be in contact with walls of the vessel. The element may comprise a coating to prevent the element from contacting chemicals in the vessel. Suitable coating materials may be inert to corrosive chemicals. Suitable coating materials include polymer materials.

Suitable electromagnetic heating means include radio-frequency heating means and microwave heating means. Preferably the electromagnetic heating means is a radio-frequency heating means.

In some embodiments the vessels are suitably adapted to receive removable vessel inserts.

Preferably the size and shape of the vessel inserts are complimentary to the size and shape of the vessels. Suitable materials for the construction of the vessel inserts include glass. The vessel inserts may be pre-loaded with chemicals. Suitable chemicals include catalysts and supported reagents. Suitable supported reagents include reagents supported on polymers.

The apparatus may comprise a main body which comprises the vessels and the conduits. The main body of the apparatus may have the form of a plate. A plate suitably has three dimensions wherein one dimension is significantly smaller than the other two dimensions. The vessels of the plate may be arranged in the plate such that the centre-points of the vessels are substantially co-planar. Suitably at least 50 % of the vessels of the apparatus are arranged in the plate such that the centre-points of the vessels are substantially co-planar. Suitably substantially all of the vessels of the apparatus are arranged in the plate such that the centre- points of the vessels are substantially co-planar. Suitably the plane comprising the centre-points of the vessels is parallel to or coincident with the plane defined by the two larger dimensions of the plate.

Suitably the vessels are arranged in a plate in substantially straight parallel rows. The rows of the vessels may be arranged so that vessels in adjacent rows are substantially aligned in straight lines along an axis parallel to the plane of the plate defined by the larger two dimensions and perpendicular to the rows. In some embodiments the rows of the vessels are off-set with respect to the vessels in the adjacent rows so that vessels in adjacent rows are not aligned in a straight line.

In embodiments wherein the vessels are arranged in substantially straight parallel rows, the apparatus may comprise a conduit network comprising a main conduit and secondary conduits wherein the main conduit comprises at least one opening to the exterior of the plate and connects to the secondary conduits, and the secondary conduits connect to vessels in adjacent rows. Suitably the secondary conduits connect the main conduit to substantially all of the vessels in the adjacent rows.

Suitably the apparatus comprises more than one part which are fastened together to form the main body of the apparatus. Suitably the apparatus comprises two parts which are fastened together to form the main body of the apparatus. Suitably one of the parts comprises cavities to provide the vessels of the apparatus and channels to provide the conduits of the apparatus.

Preferably both of the two parts comprise cavities to provide the vessels of the apparatus and channels to provide the conduits of the apparatus. Suitably the two parts may be fastened together so that the cavities and channels of one part are in alignment with the cavities and channels of the second part to provide the vessels and the conduits of the main body of the apparatus. Preferably the two parts are substantially identical.

The two parts may be provided with screws or bolts to fasten the parts to each other. In some embodiments the two parts may be clamped together.

Suitably the vessels and conduits formed by fastening the two parts together are sealed such that fluid does not leak out of the vessels and conduits into the interface of the two parts of the main body. The vessels and conduits may be sealed by providing a sealant material in the interface of the two parts. Suitably the sealant material is arranged adjacent to the edges of the cavities and channels which form the vessels and conduits of the apparatus. The sealant material may be provided on one or both of the two parts. Suitable sealant materials include rubber and synthetic rubber materials.

The apparatus may comprise a supply of a least one chemical such that the at least one chemical can be transferred from the supply to at least one vessel of the apparatus. Suitably the supply of at least one chemical is a container comprising the chemical and connected to at least one vessel of the apparatus by a conduit. Suitably the chemical is a fluid. The fluid may be a solution, a suspension or a neat chemical. Suitable chemicals include crude oil and crude oil derivatives. Suitable crude oil derivatives include products of fractional distillation of crude oil and products of cracking of crude oil. Suitably the apparatus comprises more than one supply of at least one chemical.

The apparatus may comprise at least one pump adapted to actuate mass transfer between the vessels of the apparatus and between the vessels and the exterior of the apparatus. Suitably the apparatus comprises more than one pump.

Suitably the apparatus can be set-up in use to perform a single chemical process step or a sequence of chemical process steps which are linear, divergent, convergent or any combination thereof.

The apparatus may be adapted so that it is interoperable with at least one other similar apparatus. For example the apparatus may comprise external tubing to allow the passage of fluids between the apparatus and another similar apparatus. The other similar apparatus may independently have any feature of the apparatus described above.

According to a second aspect of the present invention there is provided an assembly comprising a first apparatus according to the first aspect and a second apparatus according to the first aspect.

The first and second apparatus of this second aspect may have any of the features of the apparatus according to the first aspect.

Suitably the apparatus are connected so that mass transfer is possible between at least one vessel of a first apparatus and at least one vessel of a second apparatus. Mass transfer between the first and second apparatus may be facilitated by the communication of a conduit of the first apparatus with a conduit of the second apparatus. The assembly may be provided with external tubing to allow the passage of fluids between the first and second apparatus. In alternative embodiments the first and second apparatus may be arranged in contact with each other such that a conduit of the first apparatus connects directly to a conduit of the second apparatus.

In some embodiments the first and second apparatus can be stacked to form the assembly of this second aspect.

In embodiments wherein the apparatus has the form of a plate, at least two apparatus may be stacked such that the plane of the two larger dimensions of the first apparatus is above or below and parallel to the plane of the two larger dimensions of the second apparatus.

Stacking of at least two apparatus in this manner may provide an assembly with a three dimensional array of vessels.

In embodiments wherein the apparatus has the form of a plate, at least two apparatus may be arranged such that the plane of the two larger dimensions of the first apparatus is co-planar with the plane of the two larger dimensions of the second apparatus. Such an assembly may be provided with one or more further apparatus according to the first aspect by stacking the one or more further apparatus onto the assembly to provide a three dimensional array of vessels.

According to a third aspect of the present invention there is provided a method of carrying out chemical process steps comprising the steps of: (a) transferring at least one chemical from a container into at least one vessel in an apparatus comprising more than one vessel; (b) carrying out a chemical process step in the at least one vessel of the apparatus by heating the at least one chemical with an electromagnetic heating means to provide a product mixture; (c) optionally transferring at least part of the product mixture into a further vessel of the apparatus and carrying out a further chemical process step by heating the product mixture with an electromagnetic heating means to produce another product mixture; (d) optionally repeating step (c); (e) removing at least part of the product mixture from the apparatus; and (f) optionally subjecting the product mixture to further chemical process steps.

An apparatus of the first aspect may be used to carry out the method of this third aspect.

An assembly of the second aspect may be used to carry out the method of this third aspect.

Step (a) may involve transferring at least one chemical from a container into at least one vessel in an apparatus comprising more than one vessel. Step (a) may involve transferring at least one chemical from a container into more than one vessel in order to carry out a single chemical process step in more than one vessel. For example this may be beneficial in a case where a chemical process step is more efficient on a small scale than on a larger scale and therefore carrying out a plurality of small scale chemical process steps is more efficient than carrying out a single larger scale chemical process step.

The further chemical process step referred to in step (c) may be substantially the same as the chemical process step carried out in step (b). The further chemical process step may be different to the chemical process step carried out in step (b).

In step (d), step (c) may be repeated more than once. The number of times step (c) may be repeated may be limited by the number of vessels in the apparatus. In embodiments wherein the vessels are connected in series, step (c) may be repeated in order to carry out a linear sequence of chemical process steps. For example the vessels may be provided with different chemicals and may be heated to different temperatures.

In some embodiments step (c) may be repeated in order to carry out a sequence of chemical process steps which diverges and/or converges. For example two linear sequences of chemical process steps may be carried out in two sequences of vessels connected in series, each sequence comprising a vessel in which a final process step of the respective linear sequence takes place. Said vessels in each sequence may be connected to a further vessel such that the product mixtures from said vessels may be combined in the further vessel for a further chemical process step to be carried out.

Alternatively a single linear sequence of chemical process steps may be carried out in a single sequence of vessels connected in series comprising a vessel in which a final process step of the linear sequence takes place. Said vessel of the single linear sequence may be connected to at least two further vessels such that the product mixture from said vessel can be transferred to the further vessels for at least one further chemical process step to be carried out In some embodiments step (c) may be repeated in order to carry out a sequence of chemical process steps which involve a repetition of substantially the same chemical step. For example the vessels may be provided with the same chemicals.

Suitable further chemical process steps of step (f) include distillation, chromatography, concentration, aqueous extraction and any combination thereof. A product of the further chemical process step(s) may be transferred back into the apparatus or transferred into a second apparatus.

Step (f) may involve transferring the product mixture back into the apparatus or transferring the product mixture to a second apparatus. Step (f) may involve repeating the sequence of steps (a) to (e) once. Step (f) may involve repeating the sequence of steps (a) to (e) more than once.

In a first embodiment of the method of this third aspect involves the catalytic cracking of crude oil or crude oil derivatives. Suitably the at least one chemical provided in step (a) is crude oil or a crude oil derivative. Suitable crude oil derivatives include products of fractional distillation of crude oil and products of cracking of crude oil.

The method suitably provides a product mixture comprising a higher proportion of lighter oil fractions than the starting crude oil or crude oil derivative.

Suitably the chemical process steps carried out in the method include catalytic cracking of the crude oil or the crude oil derivative. Preferably the catalytic cracking process is a hydrocracking process.

The vessels in which the catalytic cracking processes are carried out may be provided with a catalyst. Preferably the catalyst is a dielectric material which can be heated by an electromagnetic heating means. Suitable catalysts include catalysts which comprise nickel, catalysts which comprise cobalt, mixed-oxide catalysts comprising nickel and cobalt, and zeolites. Suitably the zeolite catalysts comprise nickel or cobalt or a mixture thereof. Suitable zeolite catalysts include zeolite 5A and zeolite 13X. Suitably the catalyst is provided as a solid, for example the catalyst may be formed into a disc-shaped mass and placed in the vessels. Suitably the catalyst is porous.

The catalyst in the vessels in which the catalytic cracking processes are carried out may be heated to a temperature in the range 600 DC to 700 °C. Suitably the catalyst in all of the vessels in which the catalytic cracking processes are carried out are heated to substantially the same temperature. Suitably the temperature of the crude oil or the crude oil derivative in the vessels in which the catalytic cracking processes are carried out is between 40 °C and DC during the catalytic cracking processes.

The method may involve pumping the crude oil or crude oil derivative through two vessels of the apparatus which are connected in series in order to carry out sequential catalytic cracking processes on the crude oil or crude oil derivative passing through the apparatus. Suitably the method involves pumping the crude oil or crude oil derivative through more than two vessels of the apparatus which are connected in series in order to carry out sequential catalytic cracking processes on the crude oil or crude oil derivative passing through the apparatus.

Suitably the crude oil or the crude oil derivative comprises water. Suitably the crude oil or the crude oil derivative comprises I to 5 wt % water. Suitably the crude oil or the crude oil derivative comprises water and detergents.

The method may involve pumping the crude oil or crude oil derivative through two vessels of the apparatus which are connected in parallel in order to carry out simultaneous catalytic cracking processes on portions of the crude oil or crude oil derivative passing through the apparatus. Suitably the method involves pumping the crude oil or crude oil derivative through more than two vessels of the apparatus which are connected in parallel in order to carry out simultaneous catalytic cracking processes on portions of the crude oil or crude oil derivative passing through the apparatus.

The method may involve pumping the crude oil or crude oil derivative through two groups of vessels of the apparatus, wherein the vessels within the groups are connected in series and the groups of vessels are connected in parallel, in order to simultaneously carry out sequential catalytic cracking processes on portions of the crude oil or crude oil derivatives passing through the apparatus. Suitably the method involves pumping the crude oil or crude oil derivative through more than two such groups of vessels of the apparatus.

In a second embodiment of the method of this third aspect involves treating contaminated water. Suitably the at least one chemical provided in step (a) is contaminated water. The water may be waste water. Suitable sources of waste water include waste water from industrial processes or waste water from agriculture.

Suitably the treating of the contaminated water provides a product mixture which is less toxic than the contaminated water.

Suitably the chemical process steps carried out in the method include chemically modifying at least one chemical contaminant in the water. The at least one chemical contaminant may be modified by breaking at least one chemical bond of the chemical contaminant to provide at least two chemicals with a lower molecular weight than the chemical contaminant. Breaking the at least one chemical bond may be carried out using a catalyst. The at least two chemicals from the chemical contaminant may be less toxic than the chemical contaminant. Suitable chemical contaminants include aromatic compounds, for example bis-phenol compounds.

The vessels in which the chemical modification of the at least one chemical contaminant is carried out may be provided with a catalyst. Preferably the catalyst is a dielectric material which can be heated by an electromagnetic heating means. Suitable catalysts include catalysts which comprise nickel, catalysts which comprise cobalt, mixed-oxide catalyst comprising nickel and cobalt, and zeolites. Suitably the zeolite catalysts comprise nickel or cobalt or a mixture thereof. Suitably the catalyst is provided as a solid, for example the catalyst may be formed into a disc-shaped mass and placed in the vessels.

The vessels in which the chemical modification of the at least one chemical contaminant is carried out may be provided with a substance which emits UV light when irradiated with electromagnetic radiation. Suitable substances include mercury and gases of Group VIII of the periodic table of elements.

The vessels in which the chemical modification of the at least one chemical contaminant is carried out may be heated. Suitably all of the vessels in which the catalytic cracking processes are carried out are heated to substantially the same temperature.

The method may involve pumping the contaminated water through two vessels of the apparatus which are connected in series in order to carry out the treatment processes on the contaminated water passing through the apparatus. Suitably the method involves pumping the contaminated water through more than two vessels of the apparatus which are connected in series in order to carry out sequential treatment processes on the contaminated water passing through the apparatus.

The method may involve pumping the contaminated water through two vessels of the apparatus which are connected in parallel in order to carry out simultaneous treatment processes on portions of the contaminated water passing through the apparatus. Suitably the method involves pumping the contaminated water through more than two vessels of the apparatus which are connected in parallel in order to carry out simultaneous treatment processes on portions of the contaminated water passing through the apparatus.

The method may involve pumping the contaminated water through two groups of vessels of the apparatus, wherein the vessels within the groups are connected in series and the groups of vessels are connected in parallel, in order to simultaneously carry out sequential treatment processes on portions of the contaminated water passing through the apparatus. Suitably the method involves pumping the contaminated water through more than two such groups of vessels of the apparatus.

The method may involve a step of fermenting the contaminated water after it has been pumped through the apparatus.

According to a fourth aspect of the present invention there is provided the use of an apparatus according to the first aspect for conducting at least one chemical process step.

The apparatus may have any feature described in relation to the first aspect According to a fifth aspect of the present invention there is provided the use of an assembly according to the second aspect for conducting at least one chemical process step.

The assembly may have any of the features described in relation to the second aspect.

Specific embodiments of the invention will now be further described with reference to the accompanying drawings in which: Figure 1 shows a perspective view of a part of an apparatus comprising thirty cavities.

Figure 2 shows a close-up perspective view of a cavity of the part of an apparatus comprising thirty cavities shown in Figure 1, the cavity being provided with a radio-frequency heating coil.

Figure 3 shows a perspective view of an apparatus formed from two of the parts shown in Figure 1.

Figure 4 shows a cross-section view, along line 4 in Figure 3, of an apparatus formed from two of the parts shown in Figure 1.

Figure 5 shows a perspective view of a part of an apparatus comprising thirty cavities.

Figure 6 shows a perspective view of a part of an apparatus comprising thirty cavities.

The Figures show aspects of apparatus for conducting chemical process steps. The apparatus is formed from two parts which are fastened together. The apparatus comprises vessels for conducting chemical process steps; and conduits for transferring chemicals into the vessels from the exterior of the apparatus and for transferring products from the vessels to the exterior of the apparatus. The apparatus comprises vessels connected by conduits for transferring chemicals between the vessels. The vessels are provided with radio-frequency heating means for heating the contents of the vessels to promote chemical process steps.

The apparatus may be used to carry out chemical process steps by providing the vessels with a catalyst, pumping chemicals into a vessel, heating the catalyst in that vessel using the radio-frequency heating means, pumping a product mixture from the vessel into a second vessel and heating the catalyst in the second vessel using a radio frequency heating means. The product mixture formed by this process may be pumped into further vessels in the apparatus and subjected to further chemical process steps or may be pumped out of the apparatus.

Figures Ito 4 show aspects of one embodiment of the apparatus. In Figure 1, part (100) of an apparatus is constructed from glass. The part 000) has a plate structure having three dimensions wherein one dimension is significantly smaller than the other two dimensions. The part (100) comprises thirty cavities (120), twelve main channels (110) and sixty secondary channels (112). The cavities (120) are arranged in the plate in six substantially straight rows of five cavities. Each row of five cavities is provided with ten secondary channels and two main channels. Each cavity is connected to two secondary channels; these two secondary channels connect to different main channels. Each main channel comprises two ends (111) which are open to the exterior of the part at edges of the pad body. The main channels and secondary channels are arranged to connect the five cavities within each row in parallel. Each vessel is provided with a radio-frequency heating means which is not shown.

In Figure 2, electromagnetic heating coils (221) are shown which are associated with each cavity (220). The electromagnetic heating plate-like electrodes are not shown. The electromagnetic heating coils are of a size and shape complimentary to the cavities and are covered with a polymer coating material and connected to an electrical circuit (not shown) through the opposite face of the part (200) to that shown in the Figure. The tubes may be copper tubes or copper wire. The cavities and channels have the same configuration as the part (100) shown in Figure 1.

Figure 3 shows an apparatus (300) which comprises two parts (301) which have the configuration of cavities and vessels described above. The two parts (301) are connected together at their faces comprising the cavities and channels such that the cavities of the first part align with the cavities of the second part to provide vessels, and the channels of the first part align with the channels of the second part to provide conduits. Therefore the two-pad bodies provide an apparatus comprising thirty vessels (320), twelve main conduits (310) and sixty secondary conduits (312).

In use the apparatus may be provided with one or more sources of chemicals and one or more pumps, arranged so that one or more chemicals may be pumped into each of the five vessels in a row. One of the ends of each of the main conduits (310) may be closed or blocked such that each row has a main conduit with an opening for chemicals to be pumped into the vessels in that row and each row has a main conduit with an opening for product mixtures to be pumped out of the vessels in each row. The chemicals flow through an opening in a main conduit, through the secondary conduits which connect to that main conduit and into the vessels connected to those secondary conduits. The chemical process steps are carried out in the vessels by providing the vessels with a catalyst which can be heated by an electromagnetic heating means and heating the catalyst with the electromagnetic comprising a coil (121, Figure 1) and two plate-like electrodes (not shown). The chemical process steps may transform the chemicals into product mixtures. The product mixtures flow out of the vessels through the other secondary conduits which connect to the vessels, through the main conduit which connects to those secondary vessels and through the opening of the main conduit.

In use the apparatus may be provided with a means of connecting one main conduit to another, for example tubing. The means of connecting one main conduit to another may be arranged to direct the product mixtures flowing out of the vessels in a row into the vessels in another row for subsequent chemical process steps to be carried out.

The part (500) of an apparatus shown in Figure 5 is constructed from glass. The part (500) has a plate structure having three dimensions wherein one dimension is significantly smaller than the other two dimensions. The part (500) comprises thirty cavities (520), six main channels (510) and forty-five secondary channels (512). The cavities (520) are arranged in the plate in three blocks of ten cavities. Each block of ten cavities comprises two rows of five cavities. The five cavities in each row are each connected by secondary channels (512) to a main channel (510) and also are each connected by secondary channels (513) to a vessel in the adjacent row of that block. Each block comprises a parallel arrangement of five groups of two cavities connected in series. Each main channel comprises two ends (511) which are open to the exterior of the part at edges of the part. The vessels are provided with electromagnetic heating coils and plate-like electrodes which are not shown, but the coils are as illustrated in the embodiment of Figures ito 4.

In use two parts (500) are connected together as described above to provide an apparatus and the vessels are provided with a catalyst. Chemicals are introduced into the apparatus and chemical process steps carried out in the vessels as described above in relation to Figure 4.

In addition to the sequence of steps described above in relation to Figure 4, the use of the apparatus formed from two parts (500) involves an additional step of pumping the product mixture from each vessel in a row into a further vessel in an adjacent row, within the same block, through secondary conduits. A further chemical process step is carried out in the further vessels.

The part (600) of an apparatus shown in Figure 6 is constructed from glass. The part (600) has a plate structure having three dimensions wherein one dimension is significantly smaller than the other two dimensions. The part (600) comprises thirty cavities (620), two main channels (610) and thirty-five secondary channels (612). The cavities (620) are arranged in the plate in five rows of six cavities. The six cavities in each row are connected in series through secondary channels (613). The rows of six cavities are connected in parallel through secondary channels (612) and main channels (610). Therefore the cavities are configured in a parallel arrangement of five rows of six cavities connected in series. Each main channel comprises two ends (611) which are open to the exterior of the part at edges of the part. The use of the parts (600) to form an apparatus and carry out chemical process steps is as described above in relation to Figures 4 and 5. However the additional step of pumping the product mixture from each vessel in a row into a further vessel is repeated four times; a chemical process step being carried out in each of the six vessels in the rows connected in series.

Eaxmple I -hydrocracking of crude oil The apparatus of Fig. 3 was provided with valves to close one end (311) of each main conduit (310). The other end of each main conduit is either connected to an end of a main conduit of an adjacent row with tubing or connected to a tube for supplying the apparatus with crude oil or a tube for removing a product mixture from the apparatus. The tubing and the valves are arranged to provide a path for an incoming crude oil mixture to pass through each row of vessels in turn and then be removed from the apparatus. Each vessel is provided with a wet zeolite catalyst. A crude oil mixture comprising detergents and 1 to 5 wt% water was pumped through the apparatus with a residence time in the apparatus of between 10 and 120 seconds.

The catalyst in each vessel was heated to between 600 °C and 700 °C by the electromagnetic heating means, causing the crude oil to undergo catalytic cracking processes. The product mixture which flowed out of the apparatus comprised gases which were vented before transferring the product mixture to a further apparatus or means for purifying the product mixture.

Example 2 -treating waste water The apparatus of Figure 3 was arranged and provided with zeolite catalysts as described above in Example 1. Contaminated water comprising a substance which emits UV light when irradiated with electromagnetic radiation was pumped through the apparatus with a residence time in the apparatus of between 10 and 120 seconds. The catalyst in each vessel was heated to between 600 °C and 700 °C and the substance which emits UV light when irradiated with electromagnetic radiation was activated by the electromagnetic heating means, causing the contaminated water to undergo chemical modification. The product mixture flowing out of the apparatus was transferred to a further apparatus or means for purifying the product mixture.

Claims

Claims 1. An apparatus for conducting chemical process steps comprising at least two vessels connected by a conduit for passage of fluid between the vessels, wherein said at least two vessels comprise openings to the exterior of the apparatus for introducing chemicals into the apparatus and for removing products from the apparatus and wherein the apparatus comprises electromagnetic heating means for heating the contents of the at least two vessels.
2. The apparatus according to claim 1, wherein the vessels are constructed from glass.
3. The apparatus according to claim 1 or 2, wherein the apparatus is be constructed from glass.
4. The apparatus according to any preceding claim, comprising at least four vessels connected by conduits for passage of fluid between the vessels.
5. The apparatus according to any preceding claim, comprising more than one group of vessels connected by conduits.
6. The apparatus according to any preceding claim, comprising from four to one-hundred vessels connected by conduits for passage of fluid between the vessels.
7. The apparatus according to any preceding claim, wherein the vessels have a volume of from 1 cm3 to 10,000 cm3.
8. The apparatus according to any preceding claim, wherein more than 50 % of the vessels have the same volume.
9. The apparatus according to any preceding claim, wherein the at least two vessels connected by a conduit are connected in series.
The apparatus according to any one of claims 1 to 8, wherein the at least two vessels connected by a conduit are connected in parallel.
11. The apparatus according to any preceding claim, comprising more than one group of vessels connected in series.
12. The apparatus according to any preceding claim, comprising at least four conduits arranged in a conduit network.
13. The apparatus according to any preceding claim, comprising vessels which are connected in a combination of series and parallel arrangements.
14. The apparatus according to any preceding claim, wherein the vessels of the apparatus comprise a catalyst.
15. The apparatus according to claim 14, wherein the catalyst is suitable for carrying out a catalytic cracking process.
16. The apparatus according to claim 14 or 15, wherein the catalyst is a dielectric material which can be heated by an electromagnetic heating means.
17. The apparatus according to any of claims 14 to 16, wherein the catalyst is selected from catalysts which comprise nickel, catalysts which comprise cobalt, mixed-oxide catalysts comprising nickel and cobalt, and zeolites.
18. The apparatus according to claim 17, wherein the catalyst is a zeolite catalyst comprising nickel or cobalt or a mixture thereof.
19. The apparatus according to any of claims 14 to 18, wherein the catalyst is provided as a solid.
20. The apparatus according to claim 19, wherein the catalyst is a disc-shaped mass.
21. The apparatus according to any preceding claim, wherein the apparatus is provided with electromagnetic heating means for heating the contents of the at least two vessels.
22. The apparatus according to claim 21, wherein the electromagnetic heating means is a dielectric heating means.
23. The apparatus according to claim 21, wherein the electromagnetic heating means is an induction heating means.
24. The apparatus according to claim 21, wherein the electromagnetic heating means is a radio-frequency heating means.
25. The apparatus according to claim 21, wherein the electromagnetic heating means is a microwave heating means.
26. The apparatus according to any of claims 21 to 25, wherein the electromagnetic heating means comprises a wire coil and two plate-like electrodes.
27. The apparatus according to claim 26, wherein one or more vessels of the apparatus are positioned within the coil and between the two plate-like electrodes in order for their contents to be heated by the electromagnetic heating means.
28. The apparatus according to any one of claims 21 to 27, comprising more than one electromagnetic heating means which is adapted to heat the contents of more than one vessel.
29. The apparatus according to any one of claims 21 to 27, comprising more than one electromagnetic heating means which is adapted to heat the contents of a single vessel.
30. The apparatus according to any preceding claim, wherein the vessels are suitably adapted to receive removable vessel inserts.
31. The apparatus according to claim 30, wherein the vessel inserts are pre-loaded with chemicals.
32. The apparatus according to claim 31, wherein the vessel inserts are pre-loaded with catalysts.
33. The apparatus according to any preceding claim, comprising a main body which comprises the vessels and the conduits.
34. The apparatus according to claim 33, wherein the main body of the apparatus has the form of a plate.
35. The apparatus according to claim 34, wherein the vessels are arranged in the plate in substantially straight parallel rows.
36. The apparatus according to any preceding claim, comprising more than one part which are fastened together to form the main body of the apparatus.
37. The apparatus according to claim 36, wherein the two parts are substantially identical.
38. The apparatus according to claim 36 or 37, wherein the vessels and conduits are sealed by providing a sealant material in the interface of the two parts.
39. The apparatus according to any preceding claim, comprising a supply of a least one chemical such that the at least one chemical can be transferred from the supply to at least one vessel of the apparatus.
40. The apparatus according to claim 39, wherein the chemical is a fluid.
41. The apparatus according to claim 39 or 40, wherein the chemical is crude oil or a crude oil derivative.
42. The apparatus according to any preceding claim, comprising at least one pump adapted to actuate mass transfer between the vessels of the apparatus and between the vessels and the exterior of the apparatus.
43. An assembly comprising a first apparatus according to any of claims 1 to 42 and a second apparatus to any of claims 1 to 42.
44. The assembly according to claim 43, comprising external tubing to allow the passage of fluids between the first and second apparatus.
45. The assembly according to claim 43, wherein the first and second apparatus are arranged in contact with each other such that a conduit of the first apparatus connects directly to a conduit of the second apparatus.
46. The assembly according to claim 43 or 44, wherein the first and second apparatus are stacked to form the assembly.
47. A method of carrying out chemical process steps comprising the steps of: (a) transferring at least one chemical from a container into at least one vessel in an apparatus comprising more than one vessel; (b) carrying out a chemical process step in the at least one vessel of the apparatus by heating the at least one chemical with an electromagnetic heating means to provide a product mixture; (c) optionally transferring at least part of the product mixture into a further vessel of the apparatus and carrying out a further chemical process step by heating the product mixture with an electromagnetic heating means to produce another product mixture; (d) optionally repeating step (c); (e) removing at least part of the product mixture from the apparatus; and (f) optionally subjecting the product mixture to further chemical process steps.
48. The method according to claim 47, wherein step (a) involves transferring at least one chemical from a container into at least one vessel in the apparatus.
49. The method according to claim 47, wherein step (a) involves transferring at least one chemical from a container into more than one vessel in order to carry out a single chemical process step in more than one vessel.
50. The method according to claim 47, wherein the further chemical process step of step (c) is substantially the same as the chemical process step carried out in step (b).
51. The method according to claim 47, wherein the further chemical process step of step (c) is different to the chemical process step carried out in step (b).
52. The method according to any one of claims 47 to 51, wherein the further chemical process steps of step (f) is selected from distillation, chromatography, concentration, aqueous extraction and any combination thereof
53. The method according to any one of claims 47 to 51, wherein a product of the further chemical process step(s) is transferred back into the apparatus or transferred into a second apparatus.
54. The method according to any one of claims 47 to 53, wherein the method involves the catalytic cracking of crude oil or crude oil derivatives.
55. The method according to claim 54, wherein the catalytic cracking process is a hydrocracking process.
56. The method according to claim 54 or 55, wherein the crude oil or the crude oil derivative comprises water.
57. The method according to claim 56, wherein the crude oil or the crude oil derivative comprises I to 5 wt % water.
58. The method according to claim 56 or 57, wherein the crude oil or the crude oil derivative comprises water and detergents.
59. The method according to any one of claims 54 to 58, wherein the catalyst in the vessels in which the catalytic cracking processes are carried out is heated to a temperature in the range 600 °C to 700 °C.
60. The method according to claim 56, wherein the crude oil or the crude oil derivative in the vessels in which the catalytic cracking processes are carried out is between 40 °C and 70 °C during the catalytic cracking processes.
61. The method according to any one of claims 47 to 53, wherein the method involves treating contaminated water.
62. The method according to claim 61, wherein the water is waste water.
63. The method according to claim 62, wherein the waste water is selected from waste water from industrial processes or waste water from agriculture.
64. The method according to any one of claims 61 to 63, wherein the chemical process steps carried out in the method include chemically modifying at least one chemical contaminant in the water.
65. The method according to claim 64, wherein the at least one chemical contaminant is an aromatic compound.
66. The method according to claim 65, wherein the at least one chemical contaminant is a bis-phenol compound.
67. The method according to any one of claims 64 to 66, wherein vessels in which the chemical modification of the at least one chemical contaminant is carried out is provided with a substance which emits UV light when irradiated with electromagnetic radiation.
68. The method according to claim 67, wherein the substance is mercury.
69. The method according to claim 67, wherein the substance is a gas of Group VIII of the periodic table of elements.
70. The method according to any one of claims 61 to 69, wherein method comprises a step of fermenting the contaminated water after it has been pumped through the apparatus.
71. Use of an apparatus according any one claims 1 to 42 for conducting at least one chemical process step.
72. Use of an assembly according any one of claims 43 to 46 for conducting at least one chemical process step.
73. An apparatus, assembly, method or use substantially as described above, and/or with reference to the accompanying drawings.