Abstract: Methods of culturing microorganisms in combinations of phototrophic, mixotrophic, and heterotrophic culture conditions are disclosed. A culture of microorganisms may be transitioned between culture conditions over the life of a culture in various combinations, utilizing various conditions in a sequential manner to optimize the culture for growth or product accumulation.

Abstract: The invention describes features that can be used to control flow to an array of microchannels. The invention also describes methods in which a process stream is distributed to plural microchannels.

Abstract: The invention provides methods of making laminated devices (especially microchannel devices) in which plates are assembled and welded together. Unlike conventional microchannel devices, the inventive laminated devices can be made without brazing or diffusion bonding; thus providing significant advantages for manufacturing. Features such as expansion joints and external welded supports are also described. Laminated devices and methods of conducting unit operations in laminated devices are also described.

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: Methods of culturing microorganisms in non-axenic mixotrophic conditions are disclosed. A method of culturing microalgae mixotrophically and controlling bacterial contamination with an acetic acid/pH auxostat system is specifically described. Methods of culturing microalgae mixotrophically with an increased productivity through an increase in oxygen transfer to the culture are also described.

Abstract: This invention relates to an apparatus, comprising: a plurality of plates in a stack defining at least one process layer and at least one heat exchange layer, each plate having a peripheral edge, the peripheral edge of each plate being welded to the peripheral edge of the next adjacent plate to provide a perimeter seal for the stack, the ratio of the average surface area of each of the adjacent plates to the average penetration of the weld between the adjacent plates being at least about 100 cm2/mm. The stack may be used as the core assembly for a microchannel processor. The microchannel processor may be used for conducting one or more unit operations, including chemical reactions such as SMR reactions.

Abstract: The disclosed invention relates to a process for converting ethylbenzene to styrene, comprising: flowing a feed composition comprising ethylbenzene in at least one process microchannel in contact with at least one catalyst to dehydrogenate the ethylbenzene and form a product comprising styrene; exchanging heat between the process microchannel and at least one heat exchange channel in thermal contact with the process microchannel; and removing product from the process microchannel. Also disclosed is an apparatus comprising a process microchannel, a heat exchange channel, and a heat transfer wall positioned between the process microchannel and heat exchange channel wherein the heat transfer wall comprises a thermal resistance layer.

Abstract: The invention provides methods of making laminated devices (especially microchannel devices) in which plates are assembled and welded together. Unlike conventional microchannel devices, the inventive laminated devices can be made without brazing or diffusion bonding; thus providing significant advantages for manufacturing. Features such as expansion joints and external welded supports are also described. Laminated devices and methods of conducting unit operations in laminated devices are also described.

Abstract: The invention provides methods, apparatus and systems in which there is partial boiling of a liquid in a mini-channel or microchannel. The partial boiling removes heat from an exothermic process.

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 for converting a reactant composition comprising H2 and CO to a product comprising at least one aliphatic hydrocarbon having at least about 5 carbon atoms comprises: flowing the reactant composition through a microchannel reactor in contact with a Fischer-Tropsch catalyst to convert the reactant composition to the product, the microchannel reactor comprising a plurality of process microchannels containing the catalyst; transferring heat from the process microchannels to a heat exchanger; and removing the product from the microchannel reactor; the process producing at least about 0.5 gram of aliphatic hydrocarbon having at least about 5 carbon atoms per gram of catalyst per hour; the selectivity to methane in the product being less than about 25%. A supported catalyst comprises Co, and a microchannel reactor comprises at least one process microchannel and at least one adjacent heat exchange zone.

Abstract: Novel methods of making laminated, microchannel devices are described. Examples include: assembly from thin strips rather than sheets; and hot isostatic pressing (HIPing) to form devices with a hermetically sealed wall. Laminated microchannel articles having novel features are also described. The invention includes processes conducted using any of the articles 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: Methods of treating contamination, particularly bacterial contamination, in an open culture of microalgae with organic carbon are described herein. The methods comprise reducing the pH of a culture for a period of time and then raising the pH of the culture, wherein the culture comprises the presence of a first acid and the culture is contacted with a second acid to reduce the culture pH from a first pH value to a second pH value. The culture is maintained at the second pH value for at least 5 minutes before the culture pH is raised from the second pH value by contact with a base.

Abstract: The present invention includes Fischer-Tropsch catalysts, reactions using Fischer-Tropsch catalysts, methods of making Fischer-Tropsch catalysts, processes of hydrogenating carbon monoxide, and fuels made using these processes. The invention provides the ability to hydrogenate carbon monoxide with low contact times, good conversion rates and low methane selectivities. In a preferred method, the catalyst is made using a metal foam support.

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: Methods of treating contamination, particularly bacterial contamination, in an open culture of microalgae with organic carbon are described herein. The methods comprise reducing the pH of a culture for a period of time and then raising the pH of the culture, wherein the culture comprises the presence of a first acid and the culture is contacted with a second acid to reduce the culture pH from a first pH value to a second pH value. The culture is maintained at the second pH value for at least 5 minutes before the culture pH is raised from the second pH value by contact with a base.

Abstract: Methods for controlling series or series-parallel reactions are described. Novel microchannel apparatus having mesoporous structures adjacent to bulk flow paths are described. Methods of synthesizing formaldehyde from methanol are also described.

Abstract: The invention described herein concerns microchannel apparatus that contains, within the same device, at least one manifold and multiple connecting microchannels that connect with the manifold. For superior heat or mass flux in the device, the volume of the connecting microchannels should exceed the volume of manifold or manifolds. Methods of conducting unit operations in microchannel devices having simultaneous disrupted and non-disrupted flow through microchannels is also described.

Abstract: Bioreactor systems for culturing mixotrophic microorganisms in open cultures on a large scale are disclosed herein. Embodiments of the system comprise organic carbon delivery systems and submersible thrusters suspended on adjustable support structures.