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: The present invention includes a removable microchannel unit including an inlet orifice and an outlet orifice in fluid communication with a plurality of microchannels distributed throughout the removable microchannel unit, and a pressurized vessel adapted have the removable microchannel unit mounted thereto, the pressurized vessel adapted to contain a pressurized fluid exerting a positive gauge pressure upon at least a portion of the exterior of the removable microchannel unit. The invention also includes a microchannel unit assembly comprising a microchannel unit operation carried out within a pressurized vessel, where pressurized vessel includes a pressurized fluid exerting a positive gauge pressure upon an exterior of the microchannel unit operation, and where the microchannel unit operation includes an outlet orifice in fluid communication with an interior of the pressurized vessel.

Abstract: The invention provides methods of combusting a fuel in a reactor that includes at least 3 zones each of which contains a solid catalyst. A method of making a thermally-stable alumina support from fumed alumina is also described.

Abstract: A method for determining the maximum allowable working pressure of a microchannel device, particularly a diffusion-bonded, shim-based microchannel device operating at a temperature greater to or equal to a base material threshold temperature where significant creep may predominate, and when employing non-traditional materials of construction, when non-traditional fabrication or joining methods are used, or when spurious artifacts arise.

Abstract: The disclosed invention relates to a process and apparatus for separating a first fluid from a fluid mixture comprising the first fluid. The process comprises: (A) flowing the fluid mixture into a microchannel separator in contact with a sorption medium, the fluid mixture being maintained in the microchannel separator until at least part of the first fluid is sorbed by the sorption medium, removing non-sorbed parts of the fluid mixture from the microchannel separator; and (B) desorbing first fluid from the sorption medium and removing desorbed first fluid from the microchannel separator. The process and apparatus are suitable for separating nitrogen or methane from a fluid mixture comprising nitrogen and methane. The process and apparatus may be used for rejecting nitrogen in the upgrading of sub-quality methane.

Abstract: A new electroless plating approach to generate a porous metallic coating is described in which a metal is electrolessly deposited on a surface. Microparticles in the metal are removed to leave pores in the metal coating. Another method of forming electroless coatings is described in which a blocking ligand is attached to the surface, followed by a second coating step. The invention includes coatings and coated apparatus formed by methods of the invention. The invention also includes catalyst structures comprising a dense substrate and a porous metal adhered to the dense substrate, which is further characterized by one or more of the specified features.

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: The disclosed invention relates to a process for making an emulsion. The process comprises: flowing a first liquid through a process microchannel having a wall with an apertured section; flowing a second liquid through the apertured section into the process microchannel in contact with the first liquid, the second liquid being immiscible with the first liquid, the first liquid forming a continuous phase, and the second liquid forming a discontinuous phase dispersed in the first liquid.

Abstract: The present invention provides new microreactor systems, catalysts, and chemical processes. Methods of making novel catalysts and reaction apparatus are also described.

Abstract: Methods of dehydrogenating hydrocarbons to yield unsaturated compounds are described. Reactor configurations useful for dehydrogenation are also described. Hydrocarbons can dehydrogenationed, for relatively long periods of time-on-stream, in a reaction chamber having a dimension of 2 mm or less to produce H2 and an olefin. Techniques have been developed that reduce coke and allow stable, relatively long-term operation in small reactors.

Abstract: The invention provides methods of oxidative dehydrogenation (ODH). Conducting ODH in microchannels has unexpectedly been found to yield superior performance when compared to the same reactions at the same conditions in larger reactors. ODH methods employing a Mo—V—Mg—O catalyst is also described. Microchannel apparatus for conducting ODH is also disclosed.

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: The invention provides methods, apparatus and chemical systems for making vinyl acetate from ethylene, oxygen, and acetic acid.

Abstract: A microchannel polymerization reactor comprising: (a) a first microchannel adapted to carry a reactant stream; (b) a fluid conduit adapted to carry a fluid in thermal communication with the first microchannel; and (c) a static mixer in fluid communication with the first microchannel adapted to provide a mixing zone operative to change the cross-sectional fluid flow profile at a predetermined point along the first microchannel without changing the primary direction of the reactant stream through the first microchannel.

Abstract: A method of starting up and shutting down a microchannel process is provided. Included are the steps of providing a first multi-planar process unit, preferably adapted to process an endothermic reaction, a second multi-planar process unit, preferably adapted to process an exothermic reaction, providing a containment vessel, the containment vessel containing at least a portion of the first, and preferably the second, process unit. In startup, the microchannel process is first checked for pressure integrity by pressurizing and checking the important components of the process for leaks. Subsequently, the process units are heated by introducing a dilute low-thermal energy density material, preferably to the second process unit, followed by the introduction of a dilute high-thermal energy density material, and adjusting the proportion of high-thermal energy density material as required. In shutdown, a purge material from the containment vessel is introduced into the first, and preferably the second, process unit.

Abstract: The present invention includes methods and apparatuses that utilize microchannel technology and, more specifically in exemplary form, producing hydrogen peroxide using microchannel technology. An exemplary process for producing hydrogen peroxide comprises flowing feed streams into intimate fluid communication with one another within a process microchannel to form a reactant mixture stream comprising a hydrogen source and an oxygen source such as, without limitation, hydrogen gas and oxygen gas. Thereafter, a catalyst is contacted by the reactant mixture and is operative to convert a majority of the reactant mixture to hydrogen peroxide that is withdrawn via an egressing product stream. During the hydrogen peroxide chemical reaction, exothermic energy is generated. This exothermic energy is absorbed by the fluid within the microchannel as well as the microchannel itself.

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: 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: Methods of dehydrogenating hydrocarbons to yield unsaturated compounds are described. Reactor configurations useful for dehydrogenation are also described. Hydrocarbons can dehydrogenationed, for relatively long periods of time-on-stream, in a reaction chamber having a dimension of 2 mm or less to produce H2 and an olefin. Techniques have been developed that reduce coke and allow stable, relatively long-term operation in small reactors.

Abstract: The present invention provides new microreactor systems, catalysts, and chemical processes. Methods of making novel catalysts and reaction apparatus are also described.

Abstract: A simulated insect trapping surface for removably supporting visual representations of insects. A plurality of icons symbolizing insects, for attaching to the simulated trapping surface, and an adhesive interface between each icon and the surface for temporarily holding the icons on the surface, for teaching interpretation of an insect pattern in a sticky monitoring trap. Instead of the adhesive interface, the simulated trapping surface supports visual representations of the insects by including liquid crystal, and is transparent to light for optical projection of the representations for viewing and interpretation.