SE0950247A1

SE0950247A1 - Flödesmodul

Info

Publication number: SE0950247A1
Application number: SE0950247A
Authority: SE
Inventors: Kasper Hoeglund; Nor N Tommy; Barry Johnson
Original assignee: Alfa Laval Corp Ab
Priority date: 2009-04-15
Filing date: 2009-04-15
Publication date: 2010-10-16
Also published as: BRPI1015008B1; JP2012523955A; TWI538731B; AU2010237097A1; BRPI1015008A2; KR101705919B1; EP2419208A1; CA2757880C; ES2526995T3; CN102395425B; KR20120026478A; EP2419208B1; MX2011010722A; WO2010120234A1; JP2015051431A; CA2757880A1; PL2419208T3; PT2419208E; SE534745C2; US20120114527A1

Description

10 15 20 25 30 A further object is to provide a continuous flow module having improved pressure properties.

Accordingly, the present invention provides a solution to the above mentioned problems by a flow module comprising channel plates and utility plates. Thus the present invention relates to a channel plate, which could be used in a flow module. The channel plate comprises a plate, at least one row of units within the plate, at least one inlet and at least one outlet, wherein each unit contains one planar surface opposite a channel forming surface, and that the units are alternating in the row of units that a planar surface is adjacent to a channel forming surface, in the same row, and that the channel plate constitutes one part and the rows of units are integrated in the plate, or the channel plate is divided in midplane and constitutes two parts corresponding to each other and put together form the channel of the channel plate, or the channel plate constitutes of a frame and two formed sheets or two pressed plates, which frame and two formed sheets or two pressed plates put together form the channel of the channel plate. The channel plate according to the present invention can also comprise at least one turning box, wherein the turning box being a space or a room between two adjacent rows of units in the channel plate and one inner side of the channel plate, which turning box enables communication between the two adjacent rows of units, such that fluids may flow from one row to the other in the space or the room of the turning box.

The present invention relates also to an alternative channel plate, which channel plate comprises at least two rows of units each unit having one planar surface opposite a channel forming surface, and that the units are alternating in each row that a planar surface is adjacent to a channel forming surface in the same row, at least one turning box, at least one inlet and at least one outlet, wherein the turning box being a space or a room 10 15 20 25 30 between two adjacent rows of units in the channel plate and one inner side of the channel plate, which turning box enables communication between the two adjacent rows of units, such that fluids may flow from one row to the other in the space of the turning box. The channel plate according to the invention, could constitute one part and the rows of units are integrated in the plate, or the channel plate could be divided in midplane and constitutes two parts corresponding to each other and put together form the process channel of the channel plate, or the channel plate constitutes a frame and two formed sheets or two pressed plates, which frame and two formed sheets or two pressed plates put together form the process channel of the channel plate.

The channel plate according to the invention can also comprise a number of rows of units, a number of turning boxes. By use turning boxes it is possible to create a true three dimensional flow to give an enhanced mixing and improved heat transfer between the utility plate and the channel plate. By the use of the channel plate can high mixing rates be created and a narrow distribution of the residence time is obtained.

The present invention relates further to a flow section, which flow section comprises a channel plate, barrier plates or utility plates or combinations of barrier plates and utility plates. The channel plate can be arranged between two barrier plate, which barrier plate are sealing a channel created by the channel plate and the two barrier plates. The flow section can also comprise a channel plate arranged between two utility plates having turbulator inserts, which utility plates are sealing a channel created by the channel plate and the two utility plates, or the flow section may comprise a channel plate arranged between one barrier plate and one utility plate which are sealing a channel created by the channel plate and the two plates. The flow section may also comprise that two channel plates have a membrane or have a 10 15 20 25 30 filter applied between the two channel plates. The flow section comprises also that the two channel plates are between two barrier plates, which are sealing channels created by the channel plates and the two barrier plates, or wherein the two channel plates are arranged between two utility plates having turbulator inserts, or combinations of barrier plates and utility plates.

The flow section can also comprise gaskets which gaskets are sealing the different plates from leakage. The gasket may be a flat sheet, or multi layer sheet of a suitable material, example of such material may be multi layer expanded polytetrafluoroethylene (ePTFE), polytetrafluoroethylene (PTFE), perfuorelatomers, or fluorelastomers, polyetheretherketone (PEEK), poly- propene (PP), etc. The material of the gasket may be a soft material such as soft PEEK, PP, PTFE etc. or Viton®, Teflon®, Kalrez® etc.

The gaskets of the flow section can have a pattern corresponding to the planar surfaces of the units of the rows of units. The turbulator insert of the utility plates can have a pattern corresponding to the planar surfaces of the units of the rows of units, or both the gaskets and the turbulator insert of the utility plates can have patterns corresponding to the planar surfaces of the units of the rows of units. By this can the flow of media or the flow of fluids in the created channel have no contacts with the gasket's planar faces and little or minimized contact with any of the gaskets edges, and each turbulator insert can provide a support to the planar sides of the row of units of the channel plate.

The present invention relates also to a flat-designed continuous flow module, for instance a plate reactor, comprising different plates or sections, wherein one or more channel plates are stacked together with utility plates, barrier plates, heat exchanger plates or one or more flow sections. The flow module may comprise a stack of flow sections, and the flow module can 10 15 20 25 30 have at least one inlet for process fluids and at least one outlet for process products. One inlet could be connected to the first channel plate and one outlet could be connected to the last channel plate. The process channel could be connected parallel or could the process channel be connected in series, or both, the channel could be connected externally or the channel could be connected internally, preferably the channel is connected externally between different channel plates. One example of such arrangement could be that two channels of two channel plates are connected parallel to each other and the channels are combined in one channel of a third channel plate, which third channel plate is connected in series with the first two plates. Such an arrangement could be suitable for a two step reaction wherein the reactants are produced in the ﬁrst two channel plates and a second reaction takes place in the third channel plate.

Naturally any combinations of connections between channels could be designed for different reactions, for one step reactions or multi step reactions according to the present invention. Internal and/or external conduits are connecting the utility plates and the utility plates are connected in series or parallel or both to each other.

The flow module could also comprise a clamping device, which can be connected to the flow module, the clamping device comprises two end plates, disc springs, pistons, and tension rods, wherein piles of disc springs are thread on the pistons and are arranged as a grid of springs, one or more grids of springs are comprised in the flow module, at least one grid of springs is supported on one of the endplates to distribute clamping forces on one or more flow sections or one or more channel plates, which flow sections are placed between the two end plates, and wherein the pistons are guided through holes in the endplates having the arrangement of the grid of springs. The flow module can comprise hydraulic tools such as hydraulic cylinders or hydraulic actuators. The hydraulic tools can provide 10 15 20 25 30 tools for opening and closing of the flow module and/or they can provide pressure on the flow module plates to secure a tight sealing of the flow module.

The rows of units of the channel plate are adjacent to each other and each unite has a planar surface and a channel forming surface and the planar surface being opposite the channel forming surface. The channel forming surface according to the invention, could be selected from curved convex surface, trapezoid surface, rectangular surface, square surface, triangular surface, and the rows of units can have all channel forming surfaces selected from the same surface type or the channel forming surfaces of the rows of units could be one or more combinations of curved convex surfaces, rectangular surfaces, square surfaces, and triangular surfaces. The purpose of the shape of the channel in each channel plate is to enhance mixing or heat transfer performance in each of the channel plates. Thus could better matched total process requirements be obtained, eg for each single reaction. The channel plates in a flow module may all be the same or all may be different depending on the process requirements.

The planar surface and the channel forming surface of the units are alternating in the rows enabling a flow of fluids or media to pass the units within the row when the channel plate is assembled in the flow section or between barrier plates. The planar surfaces of the units allow a barrier plate or a utility plate to be mounted with a gasket in such a way that the channel could be sealed and leakage can be avoided. The planar surfaces could be arranged either in rows or alternating. Preferably the planar surfaces are arranged in rows. When the planar surfaces are arranged in rows it is possible to support the rows of units with the turbulator insert of the utility plate, this enables that high pressure can be applied to the channel plate and that leakage can be avoided. The channel starts with an inlet and 10 15 20 25 30 continuous through the units through out the channel plate, and the channel ends with an outlet in the last row of units. The process channel as well as the utility ﬂow of the utility plates could be connected parallel or be connected in series, or both, between two or more flow sections. The connections between the flow sections could be external or internal.

Preferably the channels of the channel plates are connected externally.

Internal and/or external conduits are connecting the utility plates of the flow sections and the utility plates are connected in series or parallel or both to each other. The inlets and the outlets of the utility plates can have ports for thermo couples, resistance thermometers etc.

The channel plate can have a number of ports connected to the channel or the turning boxes within the plate. The ports could be arranged on one, or on two sides, or on three sides, or all sides of the channel plate. This means that the ports are arranged on at least one side of the channel plate. The ports are either plugged or equipped with different equipments or the ports are combinations of plugged and equipped ports, which equipment are introduced through the ports to the channel or to the empty space of the turning boxes, and can be arranged anywhere on the channel plate. The equipment which can be introduced through the ports to the channel or the turning boxes can be selected from the group consisting of inlets for reactants, inlets for additional fluids, outlets for process fluids, outlets for intermediate products to be fed into the channel at a later stage, outlets for test samples, injection nozzles, inlet dispersers, security devices for pressure release instant or controlled, sensor units, thermo couples, resistance thermometers. The ports can have means for injection of fluids, reactants etc. such as for example a nozzle that can introduce additional fluids, re-mixing fluids, re-dispersion fluids etc. at a chosen location of the channel. The location could be anywhere, which means that the introduction of fluids could be at an inlet on the channel plate, or anywhere on the 10 15 20 25 30 channel plate, or on a second plate etc. in a flow module. A mix or a dispersion need sometime to be re-mixed or re-dispersed after some holding time or after a going through a channel plate, then it can be suitable to inject the mix or the dispersion again into the channel, this can be done between an outlet of one plate and an inlet of the next plate, and the injection can be done with any kind of suitable nozzle. The nozzles, which are inserted in the ports or the inlets, can be selected form any suitable nozzle and examples of nozzles are injection nozzles, dispersion nozzles, re-dispersion nozzles, re-mixing nozzles, coaxial nozzles, tube nozzles etc.

A coaxial nozzle could be defined as a nozzle with two or more tubes arranged within each other, that a larger tube having a large radius is surrounding a smaller tube having a smaller radius. When such a nozzle is used two or more fluids can be mixed or form dispersions. A re-mixing nozzle could be a tube nozzle having a hole with a nozzle head and the hole has a smaller radius than the tube. The nozzle may be a dispersion nozzle which can have one or more holes at the outlet of the dispersion nozzle and the holes can be arranged in concentric circles or the holes can be arranged in other suitable patterns.

The channel plate can comprise a process flow inlet and a second inlet, which could be a dispersion flow inlet or an injection inlet, at the inlet part of the channel plate, wherein the process flow inlet and the second inlet could be combined could the channel form a straight part before the first unit in the first row of units. The straight part of the channel could also end at the first turning box. The second inlet may have means for injection of fluids, reactants etc. such as for example a nozzle that can introduce additional fluids. The nozzle can be selected from any suitable type of nozzles and could be inserted at the straight part which forms a dispersion zone for introducing or injecting materials or substances into a process fluid. The inlets of fluids may also be combined before being let into the channel of the 10 15 20 25 30 channel plate. According to this alternative it is not necessary to have one inlet for process flow and another inlet for injection of fluids etc. Thus, with combined inlets outside the channel plate it is possible to only use the process flow inlet.

When producing fine dispersions in the flow by introducing a non-miscible liquid in a controlled manner and in a safe way at high velocity into the process flow in the channel, then it is crucial that the nozzle has the adequate design. The designed nozzle may be a disperser or an injector.

The nozzle may be fitted to the second inlet port of the channel plate. One or more immiscible liquid phases could simultaneously be fed through the nozzle. The designed nozzle could be a disperser having a mouthpiece in from of a closed tube with a single hole area in the closed end having a hole diameter (D), or where multiple n holes are present a diameter (D) corresponding to the of the total area of the holes divided by the number of holes n of the nozzle, which is suitably larger than the the length or depth (T) of the hole in the nozzle. The ratio may be selected so that the length of the hole is much smaller than the diameter of the hole (T< disperser is in use droplets will be sprayed out of the disperser and create a cone of droplets in the process flow. The size of the droplets that are created is depending on the pressure difference at the very outlet of the nozzle and the pressure in the compartment. lf the length of the hole (T) is large then it will be very difficult to create the desired pressure condition at that point.

For small size nozzles length (T) and diameter (D) will be very small and manufacturing limitation will occur. A favorable way to make such a nozzle is for instance to use etching, laser piercing or micro-drilling on a thin plate which then is orbital welded by laser or by electron beam on to a tube. A nozzle can produce droplets and the droplet size will depend on the flow 10 15 20 25 10 and the selected nozzle diameter. To increase flow through one nozzle it's possible to make a larger hole or to make more holes through the nozzle.

By using many small holes instead of one big hole then it is possible to create smaller droplets. To make sure to have the same pressure condition in each hole it is favourable to arrange the holes axisymmetrically relative to the main axis of the tube on which the nozzle is orbital welded. There may be several rows of holes located on concentrical circles. The hole size could be chosen according to the flow velocities for the radius of the concentrical circle or the viscosity of the fluids passing out of the holes. The spraying of materials out of the nozzle may be continuously, in a pulse-mode, or be sprayed in intervals specially adapted to the application or the process of the multipurpose flow module.

A pump may be connected for supplying and to pressurize the fluid to the nozzle. The fluid will be sprayed out of the nozzle in a cone shaped fashion.

The pump could either continuously pump fluids to the nozzle or feed the nozzle in a pulse-mode. The pulses can for example be generated by control of the pump's work cycle or by a valve in the feed line to the nozzle.

The pump is suitably controlled to maintain a given pressure level. lf the nozzle is fed in pulse-mode then it could be important that the volume between nozzle and pulse valve does not change with pressure. The duty cycle of the valve, i.e. the open time is less or equal to 100% of the total period time and is i 0%, can be controlled to give a given flow rate, which can be seen below. 10 15 20 25 11 I Period time I 5V = open OV = closed 4-> Open time Duty cycle = Open time / Period time The nozzle can be operated under pulsed or un-pulsed modes, and is used for making fluids sprays at a given average flow rate. The nozzle size is selected to give a sufficient flow rate at the pressure available and the pressure level may be set to give a certain droplet size. This means that the droplet size could be adjusted by changing the pump pressure at a constant flow rate. The pump speed may be controlled to give a set flow rate through the open valve i.e. un-pulsed mode.

The planar surfaces of the channel plate are preferably arranged in parallel rows perpendicular to the channel, and the planar surfaces of the rows will support barrier plates or utility plates on both sides of the channel plate. The barrier plate may be a separate plate or integrated either with the channel plate or integrated with the utility plate. One or two heat exchanger plates could be connected to the channel plate and the heat exchanger plate could be a non-fluid heat transfer member, or a Peltier element.

The barrier plates could be brazed to the channel plate providing a sandwich type of arrangement, or may the channel plate be brazed to the utility plate according to another alternative. The barrier plates could be arranged by any suitable method to the channel plate or to the utility plate.

As mentioned before the channel plate may have one or two barrier plates arranged on one or on both flat sides of the channel plate, which barrier plates are sealing the process channel. The barrier plates could be sealed 10 15 20 25 30 12 with gaskets to the channel plate as mentioned before. The walls or the barrier plates may be of a heat conductive material, which make it possible to let a cooling or heating fluid pass outside the channel. One or more of the barrier plates may be of an insulating material for applications of the channel plates wherein special temperature requirements are needed. The material of the barrier plates may alternatively consist of a membrane of a suitable pore size to let a formed product or products to pass the membrane or for process fluids or additional material to be added through the membrane into the channel of the channel plate. A barrier plate may also be of a filter material. Combinations of barrier plates of different materials could also be possible. According to one alternative may at least one of the barrier plates contain a solid heat conductive material, an insulator material or a membrane material. According to one alternative may two channel plates be placed on both sides of a membrane. Thus, one channel plate will transport products and the other channel plate the process flow. Important features of the channel plate and the equipment surrounding the channel plate are flexibility and easy access. Therefore, the channel plate may be adapted to enable different operations such as for instance filtration, separations by membranes, mixing etc. The channel plate may be coated by one or more catalysts or have a design which enables mixing or to create a plug flow.

The channel plate can be manufactured as one piece according to one alternative, that the rows of units are integrated in the plate. The size or shape of the channel plate could be of any suitable design forming a flow channel in a flow module or a reactor. The material of the channel plate may be stainless steel, iron-based alloys, nickel-based alloys, titanium, titanium alloys, tantalum, tantalum alloys, molybdenum-base alloys, zirconium, zirconium alloys, glass, quartz, graphite, reinforced graphite, Hasteloy, or any other material resistant to the process media. Other suitable material for the channel plate are special materials such as plastic material such as 10 15 20 25 13 PEEK (polyetherether ketone), PPS (polyphenylensulfid), PTFE (polytetra- fluoroethylene), perfuorelatomers, or fluorelastomers, PP (polypropene), etc or combinations thereof.

According to one alternative may the channel plate be formed by parting the plate in its midplane that the complex structure of the channel could be simplified and more easily manufactured. The channel plate could thus be divided into two parts wherein the parts consist of square-shaped members having square cut-outs, and channel forming surface cut-outs. The two parts will be complement of each other and put together they will form the channel. Between the two parts may a gasket seal the channel of the two part channel plate.

The invention relates further to another alternative channel plate, which is comprised of two formed sheets or two pressed plates and a reactor plate or flow plate, which plate has gaskets on each planar side on to which the two formed sheets or the two pressed plates are mounted.

The channel of the channel plate may comprise a number of rows of units forming a serpentine path in the arrangement of units. Thus, a three- dimensional flow direction of the flow of fluids is developed in the channel of each channel plate. The fluids passing the “three-dimensional” channel may be pure liquids, mixtures of liquids, immiscible liquids, liquids with particles or liquids with dissolved or free gas.

The utility plates according to the invention can have a compartment for the channel plate and also one compartment for the turbulator insert and for the heat exchanger fluids. The utility plate or the heat exchanger plate is the heat exchanger part of a flow section which could comprise at least one 10 15 20 25 14 utility plate and one channel plate. The channel plate may be inserted in the compartment of the utility plate according to one alternative. According to another alternative may one channel plate be inserted between two utility plates. The channel plate could be arranged within a space created by two complementing compartments of the two utility plates. The compartment of a utility plate could surround the whole channel plate or just a part of the channel plate leaving all injection ports and ports free. The compartment of the utility plate is a space which could be an elongated square wherein the channel plate may be placed or may be integrated in. The turbulator insert of the utility plate may have wings or fins attached. The turbulator insert could also be a metallic foam. The inlets or the outlets of the utility plates and/or of the channel plates may have thermo elements inserted. The utility plate may be sectioned heat exchanger plate such as the one disclosed by WO 2008/076039.

The clamping system according to the invention is connected to the flow module for controlling the forces applied to the flow module and thus also the pressure in the module. Such clamping systems can be found in WO 2008/066447 or in SE 0801181-9. The clamping system may comprise two end plates, disc springs, and tension rods. Piles of disc springs may be arranged as a first grid of springs on one of the two end plates, and the disc springs may be supported on this first end plate. Between the two end plates may one or more flow sections be placed, on the opposite end plate, the second end plate, may further piles of disc springs be placed as a second grid of springs. Grids of disc springs can also be placed between flow sections. Tension rods may connect the two end plates to distribute tension forces to the piles of discs springs when the clamping system being in a closed position. 10 15 20 25 30 15 To seal the flow module or the reactor properly, the clamping forces have to be within a proper range. The spring arrangement, i.e. a grid of spring piles is distributing the spring force on a stack of plates of a flow module such as a plate reactor. The flow module includes one or more layers of plates stacked together. The spring force F is a function of the spring length L. The spring length will vary within the range from Lmax to Lmin, where Lmax is defined as free length at unloaded spring, and Lmin is defined as spring length at maximum compression. The maximum force Fmax is defined as spring force at maximum compression of the spring, and the spring force will therefore vary between O and Fmax. The spring force FX, which corresponds to LX, has to be larger than force F1 to make sure that no leakage will occur but the spring force should not be bigger than force Fz to not risk permanent deformations. F1 and Fz correspond to spring lengths L1 and Lz, respectively, and L1 < LX < Lz. By using springs or piles of springs, with an adequate force compression curve, a sufficient working range Lz to L1 can be achieved. The range Lz to L1 must be larger than other geometric Such discrepancies can for example be manufacturing tolerances on flatness and discrepancies from manufacturing, assembly and operation. thickness, or deformations originating from forces at assembly, or dimensional changes due to thermal expansion or material creep at operation.

The flow module according to the invention may comprise pressure release devices, which pressure release devices, may be connected to any number of ports, injection ports or to a flow channel inlet, a flow channel outlet, or to connections between flow sections. The pressure release devices may be passive or active. A passive pressure release device may be a bursting foil, but any suitable passive pressure release device may be used. An active pressure release device may be any number of injection units for quenching materials or substances, which may be acting on command from a 10 15 20 25 30 16 computer, equipped with a monitoring and control program. Another active pressure release device may be a flow-regulating device of heat exchanger fluids, which also may be acting on command from a computer equipped with a monitoring and control program. Yet another active pressure release device may be a flow-regulating device for process materials or for added materials, which also may be acting on command from a computer equipped with a monitoring and control program.

The material or the materials of the different parts of the flow module can be selected from stainless steel, iron-based alloys, nickel-based alloys, titanium, titanium alloys, tantalum, tantalum alloys, molybdenum-base alloys, zirconium, zirconium alloys, Hastalloy, glass, quartz, graphite, reinforced graphite, PEEK, PP, PTFE etc., or combinations thereof. ln the following will the invention be explained by the use of Figures 1 to 25.

The figures are for the purpose of demonstrating the invention and are not intended to limit its scope.

Brief description of the drawinqs Figure 1 is showing rows of units according to the invention.

Figure 2 is showing a channel plate according to the present invention.

Figure 3 is showing the channel plate of Figure 2 having a cut through area showing the channel and the ports according to the invenüon.

Figure 4 is showing a cross section of the channel plate according to the present invention.

Figure 5 is showing a part of a channel plate having turning boxes at the end and at the beginning of each row of units.

Figure 6 is showing a cross-section and a side view of a channel plate according to the invention. 10 15 20 25 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 17 is showing an alternative channel plate. is showing the channel of assembled channel plate of Figure 7. is showing another alternative channel plate of the present invenüon. is showing the assembled channel plate of Figure 9. is showing another version of the channel plate. is showing assembled channel plate of Figure 11. is showing a channel plate inserted between two utility plates. is showing how the channel plate is arranged between two utility plates according to one alternative of the invention. is showing a utility and how a turbulator is arranged in the utility plate. is showing an assembled flow module according to one alternative of the invention. is showing an assembled flow module of the invention having a frame, which comprises two tension rods and two end plates, which frame is holding the channel plates and the utility plates into place by aid of hydraulic cylinders. is showing an assembled flow module according to another alternative of the invention wherein both end plates are arranged with grids of springs. is showing an assembled flow module having a section line B - B. is showing section B - B and how flow section is fitted into position. is showing section B - B with flow section arranged between two tension rods. is showing three examples of channel forming surfaces according to the invention. 10 15 20 25 30 18 Figure 23 is a graph showing the Residence Time Distributions (RTDs) of Example 1.

Figure 24 is a graph showing droplet size distributions of Example 2.

Figure 25 is a graph showing temperature profile of a single flow section of Example 3.

Detailed description of the drawinqs Figure 1 is showing a few rows of units 1 according to one alternative of the invention. ln this figure the units are alternating that the outside pattern is either planar 2 or curved 3 with each planar 2 surface having four neighbouring surrounding curved surfaces 3, and visa versa. ln Figure 2 the row of units of channel plate 4 are arranged in another pattern than in Figure 1. The rows of units are lined up that they form a symmetric parallel pattern where rows of planar surfaces 2 in Y-direction have neighbouring rows of curved surfaces 3 also in Y-direction. The units are forming a channel in X-direction between curved surfaces 3 thus the rows of units according to the invention are lined up in X-direction in this figure. Figure 3 shows channel plate 4 of Figure 2 having a cut out section 5 showing channel 6 and ports 7 according to the invention. Figure 3 as well as Figure 2 show turning boxes 8 which are shown on one of the sides of the channel plate. lf the channel plate is turned the turning boxes will appear on the opposite side of the channel plate according to this alternative. Thus turning boxes 8 are lined up in Y-direction on both sides of the channel plate. The created space of turning boxes 8 is defined as the space between two rows of units and inner side 8a of the channel plate. Wall 8b is a wall between two rows of units but this wall can also be removed in some applications.

Channel inlet 9 is seen in the figure this inlet is intended for the process flow of fluids. Channel inlet 9 is combined with injection port 10 to form a straight channel part 11 for mixing or blending the process flow with injected reactants or other injected fluids. 10 15 20 25 30 19 Figure 4 shows a cross section of the channel plate according to the present invention, this figure show that turning boxes 8 are arranged on both sides of the channel plate. The figure show also ports 12 going into the channel or space within the turning box. ln Figure 4 it is shown that in turning boxes 8 turning unit 8c has a different cross section than the units of the rows. The cross section of turning unit 8c is defined as a P-section. ln ports 12 any type of equipment can be inserted such as inlets for additional reactants, inlets for additional fluids, outlets for process fluids to be tested, outlets for intermediate products to either be fed into the channel at a later stage or to be recirculated or isolated, outlets for test samples, injection nozzles, inlet dispersers, security devices for pressure release instant or controlled, sensor units, thermo couples, resistance thermometers etc.

Figure 5 shows a part of a channel plate having turning boxes 8 at the end and at the beginning of each row of units. Turning boxes 8 have two compartments 13 where the channel turns from one row of unit to another. ln Figures 2 to 5 it is evident that the units are forming one piece built up by several units forming several rows and that the rows of units are integrated in the plate. ln these figures the units are not separate instead they are fused bonded or the channel plate is machined, casted, moulded or cut or laser cut or Electrical Discharge Machining (EDM), spark eroded, from one piece of material.

Figure 6 is showing a cross-section and a side view of a channel plate according to the invention. The figure shows inlet 9 and outlet 14 and between the inlet and the outlet runs flow channel 6 in X-direction. The channel runs up and down through each unit through each row 15, which rows 15 are in X-direction in this figure, the figure shows also that the channel contains several rows of units stacked in Y-direction. On the side 10 15 20 25 30 20 view ports 12 can be seen, the side view show that a channel plate can have several ports 12. On the side view can also inlet 9, injection port 10 and outlet 14 be seen.

Figure 7 is showing an alternative design of the channel plate, wherein the plate comprises two formed sheets 16 or two pressed plates 16 and a frame 17 having walls 18. Plates 16 are placed in opposite direction in frame 17 thus creating a channel together with walls 18. Two gaskets 19 on both sides of frame 17 are sealing the channel plate. ln Figure 7 inlet 20 can be seen, but the outlet is not shown in the figure. Figure 8 is showing channel 21 of assembled channel plate of Figure 7, the figure shows also how inlet 20 is communicating with channel 21.

Figure 9 is showing another alternative channel plate of the present invention. According to this alternative is the channel plate divided in midplane into two halves 22 and 23. Half 22 fits into half 23 and a gasket 24 is sealing the channel plate according to this version of the invention. An inlet port 25 for process fluids can be seen in the figure, but the outlet is not shown in the figure. ln Figure 10 are the two halves 22 and 23 assembled and a channel 26 is created between half 22 and 23. Figure 11 is showing another version of the channel plate which is divided in midplane. According to this version are two barrier 27 plates integrated with halves 22 and 23.

Figure 12 shows how channel 26 is sealed to the outside by barrier plates 27.

Figure 13 is showing a channel plate 28 inserted between two utility plates 29. According to this alternative two barrier plates 30 are sealing process channel 31 from utility channels 32 of utility plates 29. Within utility channels 32 are heat exchanger fluids transferring the heat to and from the process fluids in process channel 31. This figure shows one alternative shape of a 10 15 20 25 21 turning box unit 33, which has a cross section of a three quarter circle forming a P-section. The figure shows also how turbulator insert 34 of the utility plate is supporting the planar side of a unit of channel plate 28. Thus, one utility plate 29 comprises utility flow channels 32, turbulator insert 34, barrier plate 30, the utility plate may also comprise other components not mentioned here. Ports 35 are communicating with process channel 31 and the ports could be equipped with different sensors, nozzles etc. O-rings can be sealing the channel plate against barrier plates 30, the O-rings can be placed in groove 36 on both sides of channel plate 28. ln groove 37 can O- rings seal utility plate 29 against barrier plates 30. Outlets or inlets 38a+b, not seen in the figure, for heat exchanger fluids are placed on the outside of utility plates 29. A port 38 for thermo couples or resistance thermometers is in position at the inlet or the outlet for the utility flow that the temperature could be monitored.

Figure 14 is showing a how channel plate 28 is arranged between two utility plates 39 and 40. Channel plate 28 fits in compartment 41 in utility plate 39, between the integrate barrier plate of compartment 41 and channel plate 28 is a gasket 42 sealing the process channel against the integrated barrier plate of compartment 41. On the other side of channel plate 28 is also a compartment in utility plate 40, not seen in the figure, which compartment is similar to compartment 41 and therefore fits channel plate 28. Gasket 42 has cut through areas corresponding to the channel of channel plate 28, that the media in the channel is in no contact with gasket 42 planar face or have little or minimized contact with any edges of gasket 42 when the plates are assembled. Figure 14 shows also connection pipes 43. Connection pipes 43 connect utility plate 39 with utility plate 40 that the heat exchanger fluids could be transported between utility plate 39 and utility plate 40. 10 15 20 25 30 22 Figure 15 is showing a utility plate according to the invention and how a turbulator 44 is arranged in the utility plate. ln Figure 15 turbulator 44 is integrated in turbulator plate 45a, turbulator plate 45a is fitted into compartment plate 45b and sealed with an O-ring not seen in the figure.

Turbulator insert 44 could also be fitted in a compartment in a utility plate according an alternative, this is not seen in the figure. Turbulator 44 has a pattern in form of rows 46a corresponding to the planar rows of the channel plate, the planar rows of the channel plate are not shown in Figure 15. Rows 46a have fins 46b for enhancing turbulence in the flow of heat exchanger fluids and thus the heat transfer. Fins 46b are designed also to correspond to the design of the channel plate, and fins 46b give extra support to the rows of units as well as extra turbulence in the heat exchanger flow. lt is important that the channel plate is supported to provide good contact pressure on gasket especially when the flow module operates under high pressure. By this design turbulator 44 supports the rows of units of the channel plate. A compartment plate 47 for a channel plate, which channel plate is not seen in the figure, is mounted to a barrier plate 48 when the utility plate is assembled. Barrier plate 49 is an integrated barrier plate having heat exchanger fluids inlet channels 50a and outlet channels 50b integrated in barrier plate 49. lnlet channel 50a and outlet channel 50b could change place depending how the flow of heat exchanger fluids go. lnlet 51 is communicating with inlet channel 50a, inlet 51 could also be an outlet when the utility flow is turned around. Port holes 52 in the plates are for transportation of heat exchanger fluids between the plates. Communication pipes 53 are fitted with a seal in port holes 52 for safe transportation of the fluids.

Figure 16 is showing assembled flow sections 54 according to one alternative of the invention. Flow sections 54 are arranged in a frame 55 and between two tension rods 56. Depending on size, weight and operation 10 15 20 25 30 23 pressure the flow module could be assemble differently, for instance a small flow module, not shown in the figure, does not need a frame 55 instead use of tension rods alone would be sufficient in some applications, if the frame is redundant then the tension rods need to be screwed together and there is a need for more tension rods than shown in this figure.

Figure 17 is showing another alternative of the invention wherein frame 55 is holding flow sections 54 into place, not shown in detail in this figure. ln this figure flow sections 54 are kept in place by the force from a grid of springs 57 and end plate 58. According to this alternative of the invention distribution plate 59a, and pressure plates 60a and 60b are placed between two end plates 58 and 61, and flow sections 54. Two distance blocks 62 are placed between end plate 61 and distribution plate 59a. Distance blocks 62 are in closed position in this figure, which can be seen in the figure where distance blocks 62 are placed between end plate 61 and distribution plate 59a, which is not the case when the distance blocks are in open position.

Distribution plate 59b is arranged between pressure plate 60b and plate 58 with grid of springs 57 between. The forces from hydraulic cylinders 63 can be released that flow sections 54 are kept into place without the aid of hydraulic cylinders 63. The force on flow sections 56 can be measured by measuring the distance between end plate 58 and how far pistons 64 have reached outside end plate 58. The two end plates 58 and 61 are positioned so that the intended number of flow sections 54 can be entered between them when in open position. The distance between the two end plates may be adjusted by choosing the number of sleeves 65 and tightening of nuts 66 on each tension rod 67.

Figure 18 is showing an assembled flow module according to another alternative of the invention wherein each of the two end plates 68a and 69a are arranged with grids of springs 68b and 69b. ln this figure the hydraulic 10 15 20 25 30 24 tools such as hydraulic cylinders or hydraulic actuators are not shown. ln some applications the hydraulic tools may be removed. Tension rods 70a and 70b are holding flow sections 71 into place in horizontal position when the flow module is clamped. Figure 18 is also showing how channel plates 72 are arranged in flow sections 71, in this view can the port holes be seen on channel plates 72. Flow sections 71 are also hold in positions by holding means 73 which are hanging from a beam 74. Figure 18 is showing port instrumentation 75 with pressure transducers as an example.

Figure 19 is showing a section line B - B on an assembled flow module with frame 76 and one flow section 71. This figure shows also two pressure plates 77a and 77b. Hydraulic tools 78a and 78b are arranged on both sides of the flow section package having pressure plates 77a and 77b between the flow section package and the hydraulic cylinders. Flow section 71 is arranged in positions at pressure plate 77a. Figures 20 and 21 are two views of section B - B showing how flow section 71 is put into position in frame 76. Figure 20 shows how flow section 71 is fitted on to tension rod 79a. The figure shows also that the top front part of flow section 71 can pass tension rod 79b and fit into place between tension rod 79a and tension rod 79b. Means 80 for mounting flow section 71 in hanging position is arranged from beam 81, in this figure are the mounting means 80 in form of hooks but any suitable means can be applied and are easily movable by roller device 82. Figure 21 shows flow section 71 in hanging position between tension rods 79a and 79b by means of hanging means 80. A gap 83 is thus formed between flow section 71 and tension rod 79a, by this arrangement is tension rod 79a not heavily loaded with by the package of flow sections 71 and only forces created by screwing together the module will be forced on tension rods 79a and 79b, since the weight of the package of flow sections 71 etc. will be on beam 81 of frame 76. Tension rods 79a and 79b are thus holding the flow section package into place sideways. 10 15 20 25 25 Figure 22 is showing three examples of rows of units forming process channel 84. The units have planar surfaces 85 which are turned towards barrier plates 86 or utility plates 86. Two channel plates can have a membrane 86 or a filter 86 between the two channel plates, not shown in the figure, the planar surfaces 85 are turned to membrane 86 or to filter 86.

The examples of Figure 22 are illustrating how channel forming surfaces 87 are forming channel 84 between plates 86. ln this figure are channel forming surfaces 87 represented by curved convex surfaces in alternative A, trapezoid surfaces in alternative B, and triangular surfaces in alternative C.

According to the invention are all suitable channel-forming surfaces included as long as process channel 84 receives the necessary properties. ln the following will the invention be illustrated by the use of Examples 1 to 3. The purpose of the Examples is to illustrate the performance of the multipurpose flow module of the invention, and is not intended to limit its scope of invention.

Example 1: Residence Time Distributions (RTDs) RTDs provide information on the axial macro mixing characteristics of a reactor. interpretation of the RTD by use of a dispersion model enables an assessment to be made of the approximation to or deviation from plug flow. ln this Example RTDs are measured by a stimulus-response technique.

Optical probes are positioned at the inlet and outlet of the process side of one flow plate of the invention, and a pulse of dye is injected upstream of the inlet probe.

Figure 23 shows that for every flow-rate selected in the range to be studied (10 - 100 l/hr), the change in absorption with time is measured, typically 10 15 20 25 26 resulting in hundreds or thousands of data points being collected over a few seconds or few minutes from each probe. These data may be block averaged. The RTD is then determined from the inlet and outlet responses by deconvoluting the following equation: Outlet response = (Exit age distribution) x (lnlet response). By fitting an axial dispersion model to the RTDs measured at the selected flow-rates, it is possible to calculate the Peclet number (Pe) for each flow-rate, which is defined by :å D (1 Pe where u is the average linear flow velocity, L is the length of the flow channel and Da is the axial dispersion coefficient. For ideal plug flow, Pe -> oo and for ideal back-mixed flow Pe -> O. That means that from a practical technical view Pe >> 1 for plug flow and Pe << 1 for full back-mixed flow.

The conditions for one flow plate of the invention were: Dimensions of the flow channel of the reactor plate were: cross-section 3.0 mm x 16 mm in average, length of the flow channel approximately 6 m.

Flow Rate = 53 l/hr; Volume of Injected Dye = 1.0 ml; Concentration of Injected Dye = 0.26 g Nigrosine /L.

The results of the measurements are summarised Figure 23, which shows the RTD collected for the one flow plate. There are neither short cuts nor stagnant regions, thus a plug ﬂow was created in the tested flow channel Figure 23 is also showing that the shape of the distribution of the dye is essentially the same at the inlet probe as at the outlet probe, which indicates that the flow in the flow channel can be considered a plug flow, which is also confirmed by the Peclet number. The Peclet number calculated from this data z 800. 10 15 20 25 27 Example 2: Nozzles A number of different injection or dispersion nozzles were tested in a reactor plate. The nozzle was operating under different pressures and flow rates and iso-dodecane was injected into water to form the “oil in water” dispersion. The injection pressures were 2, 4, 6, and 8 Bar respectively, with pressure being increased by increasing the flow rate through the nozzle, so the dodecane / water ratio is different in each test. The droplet size distributions were evaluated, and selected results are summarised in Figure 24 for a nozzle with 10 off 140 micron holes.

Table 1: Test conditions and calculated di l\/lain flow at 50 L/h.

Qto, Om PVGSS- Press. Meas. de: lk9/hl [L/h] [bar] [bar] [Um] 11.32 15.03 2.00 2.01 21,949 15.31 20.99 4.00 4.02 13,720 19.07 25.34 3.00 3.03 14,394 23.53 31.32 3.00 3.00 13,399 A higher pressure drop decreases the size of droplets produced by the nozzle. Mass-transfer rates, in a chemical reaction, are strongly dependent on interface surface area between the two media and hence decreased droplet size supports faster reaction rates.

Example 3: heat exchange ln this experiment was the thermal profile of the process fluid travelling along the flow channel of one single flow section carried out. For simplicity water was used both in the channel plate, the process fluids, and in the utility plates, the utility fluids. The flow rate of the process fluids was 25 l/hr and the flow rate of the utility fluids was 2000 l/hr. The temperature was 28 measured at different times and the results are summarized in a graph shown in Figure 25.

The present invention is further defined by the independent claims and the dependent claims.

Claims

10 15 20 25 30 Claims

1. A channel plate comprising a plate, at least one row of units, at least one inlet and at least one outlet, wherein each unit contains one planar surface opposite a channel forming surface, and that the units are alternating in the row of units that a planar surface is adjacent to a channel forming surface in the same row, and that the channel plate constitutes one part and the row of units is integrated in the plate, or the channel plate is divided in midplane and constitutes two parts corresponding to each other and put together form the channel of the channel plate, or the channel plate constitutes a frame and two formed sheets or two pressed plates, which frame and two formed sheets or two pressed plates put together form the channel of the channel plate.

2. The channel plate according to claim 1, wherein at least one turning box is arranged between two adjacent rows of units, which turning box being a space between two adjacent rows of units in the channel plate and one inner side of the channel plate, which turning box enables communication between the two adjacent rows of units, such that fluids may flow from one row to the other in the space of the turning box.

3. A channel plate comprising at least two rows of units each unit having one planar surface opposite a channel forming surface and that the units are alternating in each row that a planar surface is adjacent to a channel forming surface in the same row, at least one turning box, at least one inlet and at least one outlet, wherein the turning box being a space between two adjacent rows of units in the channel plate and one inner side of the channel plate, which turning box enables communication between the two adjacent rows of units, such that fluids may flow from one row to the other in the space of the turning box. 10 15 20 25 30 30

4. The channel plate according to claim 3, wherein the channel plate constitutes one part and the rows of units are integrated in the plate, or the channel plate is divided in midplane and constitutes two parts corresponding to each other and put together form the process channel of the channel plate, or the channel plate constitutes a frame and two formed sheets or two pressed plates, which frame and two formed sheets or two pressed plates put together form the process channel of the channel plate.

5. The channel plate according to any one of the preceding claims, wherein the channel forming surface is selected from curved convex surface, trapezoid surface, rectangular surface, square surface, triangular surface, and the rows of units have all channel forming surfaces selected from the same channel forming surface type or are the channel forming surfaces of the rows of units one or more combinations of curved convex surfaces, rectangular surfaces, square surfaces, and triangular surfaces.

6. The channel plate according to any one of the preceding claims, wherein the channel plate has a number of ports connected to the channel or to the turning boxes, the ports are arranged on at least one side of the channel plate, the ports are either plugged or equipped with different equipments or the ports are combinations of plugged and equipped ports, which equipment are introduced through the ports to the channel or to the empty space of the turning boxes.

7. The channel plate according to any one of the preceding claims, wherein the equipped ports are equipped with one or more equipments selected from the group consisting of inlets for reactants, inlets for additional fluids, outlets for process fluids, outlets for intermediate products to be fed into the channel at a later stage, outlets for test samples, inlet dispersers, security devices for release instant or controlled, units, pfeSSUfe SenSOl' 10 15 20 25 30 31 thermocouples, resistance thermometers, or nozzles selected from injection nozzles, dispersion nozzles, re-dispersion nozzles, re-mixing nozzles, coaxial nozzles, tube nozzles or combinations of equipments.

8. The channel plate according to any one of the preceding claims, wherein the channel plate comprises a process flow inlet and an additional flow inlet at the inlet part of the channel plate, wherein the process flow inlet and the additional flow inlet are combined in a straight part starting connecting a port and the channel of the channel plate, or the channel plate comprises a process flow inlet and an additional flow inlet which are combined outside channel of the channel plate.

9. The channel plate according to any one of the preceding claims, wherein a dispersion nozzle is arranged at least one inlet or at least one port, which dispersion nozzle has one or more holes at the outlet of the dispersion nozzle and wherein the holes are arranged on concentric circles

10. A flow section comprising a channel plate according to any one of claims 1 to 9, and barrier plates or utility plates or combinations of barrier plates and utility plates, wherein at least one channel plate is arranged between two barrier plates, which are sealing a channel created by the channel plate and the two barrier plates, or wherein the channel plate is arranged between two utility plates having turbulator inserts, which are sealing a channel created by the channel plate and the two utility plates, or wherein the channel plate is arranged between one barrier plate and one utility plate, which are sealing a channel created by the channel plate and the barrier plates and the utility plates, or the flow section comprises two channel plates and the two channel plates have a membrane or have a filter applied between the two channel plates and the two channel plates are between two barrier plates, or are between two utility plates having 10 15 20 25 30 32 turbulator inserts, or the two channel plates are between one barrier plate and one utility plate having a turbulator insert.

11. The flow section according to claim 10, wherein the flow section also comprises gaskets having a pattern corresponding to the planar surfaces of the units of the rows of units or wherein the turbulator insert of the utility plates has a pattern corresponding to the planar surfaces of the units of the rows of units, or both the gaskets and the turbulator of the utility plates have pattern corresponding to the planar surfaces of the units of the rows of units.

12. The flow section according to claim 10 or 11, wherein the ﬂow of media or the flow of fluids in the created channel has no contact with the gasket's planar face and little or minimized contact with any of the gaskets edges.

13. The flow section according to any one of claims 10 to 12, wherein each turbulator insert provides a support to the planar sides of the row of units of the channel plate.

14. The flow section according to any one of claims 10 to 13, wherein one or two heat exchanger plates are connected to the channel plate and the heat exchanger plate being a non-fluid heat transfer member, or a Peltier element.

15. The flow section according to any one of claims 10 to 13, wherein the utility plate has compartment for the channel plate and a compartment for a turbulator insert.

16. A flow module comprising a stack of flow sections according to any one of claims 10 to 15, wherein the flow module has at least one inlet for process fluids and at least one outlet for process products, wherein one inlet 10 15 20 33 is connected to the first channel plate and one outlet is connected to the last channel plate, and wherein the channel is connected parallel or is the channel connected in series, or both, the channel is connected externally or the channel is connected internally, preferably the channel is connected externally, and wherein internal and/or external conduits are connecting the utility plates and the utility plates are connected in series or parallel or both to each other.

17. The flow module according to claim 16, wherein a clamping device, is connected to the flow module, the clamping device comprises two end plates, disc springs, pistons, and tension rods, wherein piles of disc springs are thread on the pistons and are arranged as a grid of springs, one or more grids of springs are comprised in the flow module, at least one grid of springs is supported on at least one of the endplates to distribute clamping forces on one or more flow sections or one or more channel plates, which flow sections are placed between the two end plates, and wherein the pistons are guided through holes in the endplates having the arrangement of the grid of springs.

18. Use of a flow module according to claim 16 or 17 as a continuous plate reactor.