The invention is concerned with an apparatus for bringing about a catalytic pipe reaction and relates more specifically to a catalytic converter means for motor vehicles.
Apparatus of the kind in question are reaction devices in which a chemical pipe reaction propagates through the reaction devices or develops along the same. A pipe reaction is made use of, for instance, for the preparation of sulfuric acid or for high density ethylene polymerization or continuous styrene polymerization.
It is known to have a catalyst conveniently disposed at the path along which the pipe reaction through the reaction apparatus takes place so that the pipe reaction will turn out to be optimal. Such a catalyst may be distributed uniformly along the path. Also, it may be necessary to have different concentrations of the catalyst present in the different portions of the reaction apparatus. To this end, a catalytically inactive mixture is added to the catalyst. The ratio between the catalyst and the admixture which particularly serves to dilute the catalyst varies among the various sections along the reaction apparatus.
It is the object of the instant invention to provide an apparatus of the kind defined initially with improved distribution of the catalyst along the reaction device formed by the apparatus.
This object is met, in accordance with the invention, with an apparatus as defined in the preamble of claim 1, by an arrangement composed of a plurality of microreactors, with channels being formed each between adjacent microreactorsÿso as to produce the catalytic pipe reaction along the arrangement of the plurality of microreactors.
The essential advantage achieved by the invention over the state of the art is obtained by the possibility of providing a respective predetermined, preferably very small amount of catalyst for the pipe reaction in the plurality of microreactors along the way. In this manner, catalyst can be made available in an amount depending on the particular state of the pipe reaction in the respective microreactor to assure optimum continuance of the reaction.
According to a convenient further development of the invention substance volume transport is established between adjacent microreactors whereby the adjacent microreactors are coupled in terms of substance volume. This means that reactions requiring transportation of intermediate reaction products can be produced in the apparatus.
It is convenient to have thermal transport through the respective channel between adjacent microreactors so that the adjacent microreactors will be coupled thermally. Hereby, heat transmission is obtained between the adjacent microreactors.
In a further development of the invention, a respective channel is designed to have a length which will prevent reverse diffusion of the substance volume from one of the adjacent microreactors into another one connected upstream thereof in the direction of propagation of the reaction. That prevents the partial reaction of the pipe reaction under way in the other one of the adjacent microreactors from retroactively influencing the partial reaction of the pipe reaction taking place in the one of the adjacent microreactors.
It may be an advantage to provide for one or all of the plurality of microreactors to comprise means for influencing at least one reaction parameter of the catalytic reaction in the respective microreactor as that permits purposively varying reaction parameters of individual sections along the way of the pipe reaction as it passes through the apparatus.
According to a preferred embodiment of the invention, means for influencing at least one reaction parameter of the catalytic reaction in a first one of the plurality of microreactors are coupled to sensor means for detecting at least one reaction parameter of the catalytic reaction in a second one of the plurality of microreactors. Hereby, the coupling of the catalytic reaction in the first one of the plurality of microreactors with the catalytic reaction in the second one of the plurality of microreactors can be devised such that the at least one reaction parameter of the catalytic reaction in the first one of the plurality of microreactors can be influenced in response to the at least one reaction parameter of the catalytic reaction in the second one of the plurality of microreactors, as detected by the sensor means. In this manner the catalytic reaction can be optimized by specifically influencing parts of the ongoing reaction in the plurality of microreactors.
In a preferred further development of the invention it may be provided that the means for influencing the at least one reaction parameter of the catalytic reaction in the second one of the plurality of microreactors are coupled to sensor means for detecting at least one reaction parameterÿof the catalytic reaction in the first one of the plurality of microreactors so that coupling of the catalytic reaction in the second one of the plurality of microreactors with the catalytic reaction in the first one of the plurality of microreactors can be obtained in such a way that influencing of the at least one reaction parameter of the catalytic reaction in the second one of the plurality of microreactors can be achieved in response to the at least one reaction parameter of the catalytic reaction in the first one of the plurality of microreactors, as detected by the sensor means. This permits mutual influencing of the sections of the pipe reaction effective in the first and second of the plurality of microreactors.
In a convenient modification of the invention it is provided that the means for influencing at least one of the reaction parameters in the respective microreactor comprise a control means for temperature control in the respective microreactor. Hereby, the temperature may be raised or lowered so as to yield optimum pipe reaction.
The means for influencing at least one of the reaction parameters in the respective microreactor advantageously comprise an irradiation means for radiating light into the respective microreactor. This offers a possibility of either accelerating or protracting a photosensitive pipe reaction.
In a further development of the invention it is provided that the means for influencing at least one reaction parameter in the respective microreactor comprise supply means for introducing at least one additional reactive substance (educt) into the respective microreactor. The introduction of additional reactive substances may either accelerate or protract the pipe reaction. It is likewise possible to introduce inert substances that are required to sustain the pipe reaction, such as a carrier gas or a solvent.
It is advantageous if a state of the respective microreactor, in particular a fixed point state, a bistable state, an oscillator state, or a state of chaos is adjustable by the means for influencing at least one reaction parameter in the respective microreactor. In this manner the respective most favorable state in the respective microreactor is selectable for supporting the pipe reaction in a particular portion of the pipe reaction.
In a convenient modification of the invention, adjacent microreactors are disposed so as to be laterally offset with respect to each other. The offset, for instance, may be from about 0.05 mm to about 30 mm. That reduces the space requirement of the apparatus.
To the same end it may be provided, advantageously, that opposed sidewalls of the plurality of microreactors have a spacing between them of from about 0.02 mm to about 5 mm.
The reaction apparatus for a pipe reaction, obtained by sequentially arranging a plurality of microreactors, may be utilized benefitially as a catalytic converter means for motor vehicles. With this application, the structural design of the individual microreactors should be such that there is sufficiently great probability that the exhaust gas particles in the microreactor will contact a respective catalyst assembly, preferably made of palladium or platinum.
The invention will be described further, by way of example, with reference to the accompanying drawings, in which:
As may be seen in
When a catalytic pipe reaction is under way in the apparatus 1 the plurality of microreactors 2 and the respective channels 3 between adjacents one of them form an integral reaction device. The ongoing catalytic pipe reaction is carried on between adjacent microreactors by substance volume transport and/or thermal transport which take place between the adjacent microreactors in the direction of propagation of the pipe reaction. Provision may be made for such thermal transport between the plurality of microreactors 2 to take place also in a direction opposed to the propagating pipe reaction. That may serve for directly influencing the pipe reaction in a first one of the plurality of microreactors 2 in response to the course or state of the pipe reaction in a second one of the plurality of microreactors 2, the second of the plural microreactors 2 being connected upstream of the first of the plural microreactors 2 in the direction of the reaction. The first and second of the plurality of microreactors 2 may be adjacent ones. The thermal transport between the first and second of the plurality of microreactors 2 may be accomplished by a thermal bridge (not shown). The thermal bridge, for instance, may comprise a temperature sensor at the first of the plurality of microreactors 2, a heater/cooler element at the second of the plurality of microreactors 2, and an electrical coupling between the temperature sensor and the heater/cooler element. This would be an electrical thermal bridge. It is likewise possible to use thermal bridges which essentially rely on heat conduction. The thermal bridge may be utilized for influencing the reaction either in the direction of the propagating pipe reaction or in the opposite direction.
As regards their shape, length, width, and height, the channels 3 are designed such that reverse diffusion of the substance volume is impeded between any two adjacent ones of the plurality of microreactors 2 so that it is warranted that the pipe reaction will propagate in one direction. The channels 3 may all be of the same design. But some channels 3 may also be designed differently from others.
The sequential arrangement of the microreactors 2 which are interconnected by the channels 3, on the one hand, provides an integral reaction apparatus for producing the pipe reaction. On the other hand, part of the pipe reaction in one of the plurality of microreactors 4 also may be influenced irrespective of another part of the pipe reaction which is ongoing in another one of the plurality of microreactors 5.
One or each one of the plurality of microreactors 2 may be equipped with means (not shown) for purposively varying reaction parameters or reaction conditions in the respective microreactor in order thus to initiate, accelerate, or impede the pipe reaction in the integral reaction apparatus which is composed of the plurality of microreactors 2 and channels 3. The reaction conditions in a certain microreactor are influenced by the means provided for that particular microreactor. Coupling or joint control may be provided for the means associated with microreactors. The overall course of the catalytic pipe reaction may be influenced by changing the reaction parameters or the reaction conditions in one of the microreactors.
The means for purposively changing the reaction parameters or reaction conditions, in particular, may comprise a control means for temperature control in the respective microreactor and/or an irradiation means for radiating light into the respective microreactor. The means by which to vary the reaction parameters or the reaction conditions may be utilized for separately creating reaction conditions in the plurality of microreactors so as to exert the desired influence on the pipe reaction. Thus a state of a respective microreactor may be adjusted so that this particular microreactor will be in a fixed point state, an oscillator state, or a state of chaos.
It may be advantageous in connection with the various means for purposively varying the reaction parameters or reaction conditions in single microreactors or multiple microreactors 2 to provide for this targeted change in one or more microreactors of the apparatus 1 to be made in response to the state or course of the pipe reaction in one or more other microreactors of the apparatus 1.
Furthermore, provision may be made in one or all of the plurality of microreactors 2 for additional reactive or inert substances and/or catalysts to be introduced into the respective microreactor so as to influence the part of the pipe reaction taking place in that particular microreactor or the whole pipe reaction. To allow that, the microreactors for which such influencing is desired are provided with supply means, such as openings in the microreactors, connections, etc. The additional substances or catalysts may be introduced, for instance, by means of micropumps.
FIGS. 4 to 7 illustrate microreactors intended for use in catalytic converter means of motor vehicles which are run on petroleum based fuel. Several of the microreactors shown in FIGS. 4 to 6 are connected in series to form a catalytic converter means for motor vehicles. A micro pipe reactor thus is formed of the microreactors wherein at least substance volume flow takes place during the catalytic reaction. The desired catalytic effect on the reaction products of the fuel conversion may be obtained by a combination exclusively of microreactors of the same kind, i.e. according to either
The catalyst assembly 45 and the reaction chamber 43 or the central portion 42 must be so designed that an interaction most likely will take place due to the relative relationship between the distance A and the small-number multiple of the mean transverse diffusion length of the gas particle, to initiate a catalytic reaction of the gas particle, including the material of the catalyst assembly 45. In this manner a high catalytic efficiency of the microreactor 40 is achieved. Those skilled in the art, while observing the design characteristics specified above, can choose different structures in which a desired catalytic effect is obtained.
Conveniently, the design requirements described above are to be applied so that a gas particle passing through the microreactor will enter into an effective reaction space, and the dwelling time within the reaction space will be so long that there is sufficient likelihood that a catalytic reaction of the gas particle, including the respective catalyst assembly, will occur.
Apart from the design feasibilities illustrated in
A further increase in efficiency of the catalytic action is obtained by ligning up a plurality of microreactors 40, 50, or 60, whereby a reaction apparatus is formed in which substance volume transport takes place between the microreactors connected in series when a catalytic pipe reaction is under way. Possible embodiments of such an apparatus comprising a plurality of microreactors 80A, 81A, 82A; 80B, 81B; 80C, 81C, 82C connected in series are illustrated in
Catalyst assemblies 83A, 84A, 85A of the microreactors 80A, 81A, and 82A, respectively, each are connected by a respective electrical connection 86A, 87A, 88A to a control means 89A, 90A, and 91A, respectively. The control means 89A, 90A, 91A serve to control the supply of current to the catalyst assemblies 83A, 84A, 85A for heating the catalyst assemblies 83A, 84A, 85A in order to optimize the respective catalytic reaction. A superordinated control means (not shown) may be provided to influence the cooperation between the control means 89A, 90A, 91A. In this manner the catalytic reaction taking place along the microreactors 80A, 81A, and 82A, respectively, can be optimized so as to reduce the content of noxious components in the fuel for operating a fuel cell or in the exhaust gas of a motor vehicle when the apparatus including the microreactors 80A, 81A, 82A is employed.
In analogous manner, the microreactor combinations 80B and 81B as well as 80C, 81C, 82C illustrated in
In the embodiments according to
The microreactors or microreactor arrangements described above help prevent the undesirable pressure loss in a motor vehicle catalytic converter means that occurs with conventional catalytic converters for motor vehicles. Moreover, the above mentioned control means, such as control means 83C, 84C, 85C in
The features of the invention disclosed in the specification above, in the drawing and claims may be essential to implementing the invention in its various embodiments, both individually and in any combination.
Number | Date | Country | Kind |
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10032059.7 | Jul 2000 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/DE01/02509 | 7/4/2001 | WO | 8/25/2003 |
Number | Date | Country | |
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0025872 A1 | Feb 2004 | US |