Abstract: Integrated Combustion Reactors (ICRs) and methods of making ICRs are described in which combustion chambers (or channels) are in direct thermal contact to reaction chambers for an endothermic reaction. Particular reactor designs are also described. Processes of conducting reactions in integrated combustion reactors are described and results presented. Some of these processes are characterized by unexpected and superior results, and/or results that can not be achieved with any prior art devices.

Abstract: Novel designs for microchannel apparatus are described in which microchannels are shaped to reduce the amount of material needed to build an apparatus. In these designs, some microchannels are shaped, in cross-section, to provide relatively more structural material in areas of greatest stress, while leaving greater area for unit operations in areas of the apparatus that are subjected to relatively less stress.

Abstract: This invention relates to a process for conducting a hydrocracking or a hydrotreating process in a microchannel reactor. This invention also relates to a process and apparatus for flowing a vapor and liquid into a plurality of microchannels in a microchannel processing unit.

Abstract: The disclosed invention relates to a process for conducting an equilibrium limited chemical reaction in a microchannel reactor. The process involves the use of active heat exchange and is suitable for conducting exothermic and endothermic reactions. The process is particularly suitable for synthesizing methanol and dimethyl ether.

Abstract: The disclosed invention relates to a process, comprising: conducting unit operations in at least two process zones in a process microchannel to treat and/or form a non-Newtonian fluid, a different unit operation being conducted in each process zone; and applying an effective amount of shear stress to the non-Newtonian fluid to reduce the viscosity of the non-Newtonian fluid in each process zone, the average shear rate in one process zone differing from the average shear rate in another process zone by a factor of at least about 1.2.

Abstract: Provided is a process and apparatus for exchanging heat energy between three or more streams in a millichannel apparatus, which millichannel apparatus may comprise a heat exchanger which may be integrated with a millichannel reactor to form an integrated millichannel processing unit. The combining of a plurality of integrated millichannel apparatus to provide the benefits of large-scale operation is enabled. In particular, the millichannel heat exchanger enables flexible heat transfer between multiple streams and total heat transfer rates of about 1 Watt or more per core unit volume expressed as W/cc.

Abstract: This invention relates to a process for converting ethylene to ethylene oxide comprising: flowing reactants comprising ethylene and oxygen or a source of oxygen in a microchannel reactor in contact with a catalyst to form a product comprising ethylene oxide, the reactants undergoing an exothermic reaction in the microchannel reactor; and transferring heat from the microchannel reactor to a heat exchanger.

Abstract: Provided is a process and device for exchanging heat energy between three or more streams in a microchannel heat exchanger which can be integrated with a microchannel reactor to form an integrated microchannel processing unit. The combining of a plurality of integrated microchannel devices to provide the benefits of large-scale operation is enabled. In particular, the microchannel heat exchanger enables flexible heat transfer between multiple streams and total heat transfer rates of about 1 Watt or more per core unit volume expressed as W/cc.

Abstract: The disclosed invention relates to a process for conducting a Fischer-Tropsch reaction, comprising flowing a reactant mixture comprising fresh synthesis gas and tail gas in a microchannel reactor in contact with a catalyst to form at least one hydrocarbon product, the catalyst being derived from a catalyst precursor comprising cobalt and a surface modified catalyst support.

Abstract: Novel methods of electroless plating are described. Catalyst coatings can be applied within microchannel apparatus. Various reactions, including combustion and steam reforming, can be conducted over electroless catalyst coatings.

Abstract: The present invention provides methods, systems and apparatus in which one fluid passes through an orifice or orifices and mixes with another fluid as it flows through a microchannel.

Abstract: An apparatus is described which comprises at least one process microchannel having a height, width and length, the height being up to about 10 mm, the process microchannel having a base wall extending in one direction along the width of the process microchannel and in another direction along the length of the process microchannel; at least one fin projecting into the process microchannel from the base wall and extending along at least part of the length of the process microchannel; and a catalyst or sorption medium supported by the fin.

Abstract: The present invention provides catalysts, reactors, and methods of steam reforming over a catalyst. Surprisingly superior results and properties obtained in methods and catalysts of the present invention are also described. For example, a coated catalyst was demonstrated to be highly stable under steam reforming conditions (high temperature and high pressure of steam). Methods of making steam reforming catalysts are also described.

Abstract: Integrated Combustion Reactors (ICRs) and methods of making ICRs are described in which combustion chambers (or channels) are in direct thermal contact to reaction chambers for an endothermic reaction. Superior results were achieved for combustion chambers which contained a gap for free flow through the chamber. Particular reactor designs are also described. Processes of conducting reactions in integrated combustion reactors are described and results presented. Some of these processes are characterized by unexpected and superior results.

Abstract: This invention relates to a process comprising reacting ethylene and oxygen or a source of oxygen in a process microchannel in the presence of a catalyst to form a product comprising ethylene oxide.

Abstract: The proper sizing of microchannel dimensions and the management of internal features offer the possibility of inherently safe operation within the flammable limits of a combustible fluid stream while preserving the largest-possible flow dimensions for industrial-scale process capacity. Specifically, the microchannel dimensions need not be restricted to gap distances below the quenching distance to be operated safely. Microchannel performance can be engineered to provide adequate heat transfer for flame propagation. However, it is essential to maintain flame characteristics in such a manner that it cannot transition to a detonation flame front. A detonation takes place when the combustion wave propagates at supersonic speeds at the existing local temperature and pressure conditions in the system. It results in a much larger energy release over a much smaller period of time as compared to a laminar flame or deflagration, the later of which is a combustion wave propagating at subsonic speed.

Abstract: A process for carrying out at least two unit operations in series, the process comprising the step of: (a) directing a feed stream into an integrated assembly which comprises a first microchannel unit operation upon at least one chemical of the feed stream to generate a distributed output stream that exits the first microchannel unit operation in a first set of discrete microchannels isolating flow through the discrete microchannels; and (b) directing the distributed output stream of the first microchannel unit operation into a second microchannel unit operation as a distributed input stream, to continue isolating flow between the first set of discrete microchannels, and conducting at least one operation upon at least one chemical of the input stream to generate a product stream that exits the second microchannel unit operation, where the first microchannel unit operation and the second unit operation share a housing.

Abstract: Provided is a process and device for exchanging heat energy between three or more streams in a microchannel heat exchanger which can be integrated with a microchannel reactor to form an integrated microchannel processing unit. The combining of a plurality of integrated microchannel devices to provide the benefits of large-scale operation is enabled. In particular, the microchannel heat exchanger enables flexible heat transfer between multiple streams and total heat transfer rates of about 1 Watt or more per core unit volume expressed as W/cc.

Abstract: Novel manifolds and methods of flow through manifolds are described. Apparatus and techniques are described in which flow from a relatively large volume header is equally distributed to process channels. Methods of making laminated, microchannel devices are also described.

Abstract: A process unit comprising: (a) a first microchannel module comprising: (i) a first unit operation including microchannels, in which at least a portion of a unit operation takes place, adapted to be in fluid communication with a first inlet stream and a first outlet stream, and (ii) a second unit operation including microchannels adapted to be in thermal communication with the first unit operation, the second unit operation adapted to be in fluid communication with a second inlet stream and a second outlet stream; and (b) a pressurized vessel at least partially containing the first microchannel module adapted to be concurrently occupied by a compressive medium in thermal communication with the first microchannel module.