Abstract: The present technology is directed to processes for conversion of synthesis gas in a tubular reactor to produce a synthetic product that utilizes high activity carbon monoxide hydrogenation catalysts and a heat transfer structure that surprisingly provides for higher per pass conversion with high selectivity for the desired synthetic product without thermal runaway.

Abstract: A mounting mechanism for connecting mechanical equipment to any mounting surface has an upper (floating) portion, and a lower (fixed) portion. The mechanical equipment is mounted to the upper portion, and the lower portion is mounted to the mounting surface. The upper portion and lower portion are connected to each other via a connection mechanism—preferably a resilient connection mechanism. A restraint mechanism is attached to both the upper portion and the lower portion on the side of the upper and lower portion that faces away from the equipment. The restraint mechanism provides positive restraint at a rate of at least 5 pounds per linear inch of length but can provide much higher than that. The restraint mechanism is flexible to allow for isolation of the equipment.

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: A microchannel reactor comprising: (a) a plurality of process microchannels having particulates packed along the length of the microchannels; (b) a plurality of heat transfer microchannels in thermal communication with the plurality of process microchannels; and, (c) a first retainer positioned at a first end of the plurality of process microchannels to inhibit the particulates from exiting the process microchannels via the first end.

Abstract: A method of loading material within a microchannel device, the method comprising: (a) loading particulates into a plurality of microchannels; and, (b) ultrasonically packing the particulates into the plurality of microchannels using a portable, compact ultrasonic densification unit.

Abstract: The disclosed invention relates to a process, comprising: flowing a first reactant feed stream comprising a reactant substrate and a second reactant feed stream comprising an alkylating agent, an acylating agent or a mixture thereof, in a process microchannel in contact with each other to form a product comprising at least one alkylation product, at least one acylation product, or a mixture thereof; transferring heat from the process microchannel to a heat sink; and removing the product from the process microchannel.

Abstract: A method of loading material within a microchannel device, the method comprising: (a) loading particulates into a plurality of microchannels; and, (b) ultrasonically packing the particulates into the plurality of microchannels using a portable, compact ultrasonic densification unit.

Abstract: The disclosed invention relates to a process for conducting a multiphase reaction in a microchannel. The process comprises: forming a multiphase reaction mixture comprising a first reactant and a second reactant; the first reactant comprising at least one liquid; the second reactant comprising at least one gas, at least one liquid, or a combination of at least one gas and at least one liquid; the first reactant forming a continuous phase in the multiphase reaction mixture; the second reactant forming gas bubbles and/or liquid droplets dispersed in the continuous phase; and reacting the first reactant with the second reactant in a process microchannel in the presence of at least one catalyst to form at least one product.

Abstract: A microchannel reactor comprising: (a) a plurality of process microchannels having particulates packed along the length of the microchannels; (b) a plurality of heat transfer microchannels in thermal communication with the plurality of process microchannels; and, (c) a first retainer positioned at a first end of the plurality of process microchannels to inhibit the particulates from exiting the process microchannels via the first end.

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 distillation process for separating two or more components having different volatilities from a liquid mixture containing the components. The process employs microchannel technology for effecting the distillation and is particularly suitable for conducting difficult separations, such as the separation of ethane from ethylene, wherein the individual components are characterized by having volatilities that are very close to one another.

Abstract: The disclosed invention relates to a distillation process for separating two or more components having different volatilities from a liquid mixture containing the components. The process employs microchannel technology for effecting the distillation and is particularly suitable for conducting difficult separations, such as the separation of ethane from ethylene, wherein the individual components are characterized by having volatilities that are very close to one another.

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: The disclosed invention relates to a process for separating methane or nitrogen from a fluid mixture comprising methane and nitrogen, the process comprising: (A) flowing the fluid mixture into a microchannel separator, the microchannel separator comprising a plurality of process microchannels containing a sorption medium, the fluid mixture being maintained in the microchannel separator until at least part of the methane or nitrogen is sorbed by the sorption medium, and removing non-sorbed parts of the fluid mixture from the microchannel separator; and (B) desorbing the methane or nitrogen from the sorption medium and removing the desorbed methane or nitrogen from the microchannel separator. The process is suitable for upgrading methane from coal mines, landfills, and other sub-quality sources.

Abstract: The disclosed invention relates to a process, comprising: flowing a first reactant feed stream comprising a reactant substrate and a second reactant feed stream comprising an alkylating agent, an acylating agent or a mixture thereof, in a process microchannel in contact with each other to form a product comprising at least one alkylation product, at least one acylation product, or a mixture thereof; transferring heat from the process microchannel to a heat sink; and removing the product from the process microchannel.

Abstract: The disclosed invention relates to a process for treating or making an emulsion in a microchannel. The emulsion comprises a first liquid and a second liquid, the first liquid forming a continuous phase, the second liquid forming droplets dispersed in the continuous phase.

Abstract: The disclosed invention relates to a process for conducting a multiphase reaction in a microchannel. The process comprises: forming a multiphase reaction mixture comprising a first reactant and a second reactant; the first reactant comprising at least one liquid; the second reactant comprising at least one gas, at least one liquid, or a combination of at least one gas and at least one liquid; the first reactant forming a continuous phase in the multiphase reaction mixture; the second reactant forming gas bubbles and/or liquid droplets dispersed in the continuous phase; and reacting the first reactant with the second reactant in a process microchannel in the presence of at least one catalyst to form at least one product.

Abstract: The disclosed invention relates to a distillation process for separating two or more components having different volatilities from a liquid mixture containing the components. The process employs microchannel technology for effecting the distillation and is particularly suitable for conducting difficult separations, such as the separation of ethane from ethylene, wherein the individual components are characterized by having volatilities that are very close to one another.

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: 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.