IPC분류정보
국가/구분 |
United States(US) Patent
등록
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국제특허분류(IPC7판) |
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출원번호 |
US-0279089
(2002-10-22)
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등록번호 |
US-7404936
(2008-07-29)
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발명자
/ 주소 |
- Mazanec,Terry J.
- Wang,Yong
- Silva,Laura J.
- VanderWiel,David P.
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출원인 / 주소 |
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대리인 / 주소 |
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인용정보 |
피인용 횟수 :
20 인용 특허 :
11 |
초록
The present invention provides new microreactor systems, catalysts, and chemical processes. Methods of making novel catalysts and reaction apparatus are also described.
대표청구항
▼
We claim: 1. A method of conducting a reaction, comprising: flowing at least one reactant into a microchannel; wherein the microchannel comprises a graded catalyst; reacting the at least one reactant in the presence of the graded catalyst within the microchannel; wherein the reactant, or reactants,
We claim: 1. A method of conducting a reaction, comprising: flowing at least one reactant into a microchannel; wherein the microchannel comprises a graded catalyst; reacting the at least one reactant in the presence of the graded catalyst within the microchannel; wherein the reactant, or reactants, and catalyst are selected such that the step of reacting is selected from the group consisting of: acetylation, addition reactions, alkylation, dealkylation, hydrodealkylation, reductive alkylation, amination, ammoxidation, ammonia synthesis, aromatization, arylation, autothermal reforming, carbonylation, decarbonylation, reductive carbonylation, carboxylation, reductive carboxylation, reductive coupling, condensation, cracking, hydrocracking, cyclization, cyclooligomerization, dehalogenation, dimerization, epoxidation, esterification, exchange, Fischer-Tropsch, halogenation, hydrohalogenation, homologation, hydration, dehydration, hydrogenation, dehydrogenation, hydrocarboxylation, hydroformylation, hydrogenolysis, hydrometallation, hydrosilation, hydrolysis, hydrotreating (HDS/HDN), isomerization, methylation, demethylation, metathesis, nitration, polymerization, reduction, reformation, reverse water gas shift, Sabatier, sulfonation, telomerization, transesterification, trimerization, and water gas shift; wherein the graded catalyst has a varying thermal conductivity such that the thermal conductivity in one part of the graded catalyst is at least 50% higher than in another part of the graded catalyst; and forming at least one product. 2. The method of claim 1 further comprising a step of exchanging heat between the microchannel and an adjacent heat exchanger. 3. A method of conducting a reaction, comprising: flowing at least one reactant into a microchannel through a microchannel inlet; wherein the microchannel comprises a center; wherein the microchannel comprises a graded catalyst that has a varying thermal conductivity such that the thermal conductivity in one part of the graded catalyst is at least 25% higher than in another part of the graded catalyst; reacting the at least one reactant in the presence of the graded catalyst within the microchannel; wherein the reactant, or reactants, and catalyst are selected such that the step of reacting is selected from the group consisting of: acetylation, addition reactions, alkylation, dealkylation, hydrodealkylation, reductive alkylation, amination, ammoxidation, ammonia synthesis, aromatization, arvlation, autothermal reforming, carbonylation, decarbonylation, reductive carbonylation, carboxylation, reductive carboxylation, reductive coupling, condensation, cracking, hydrocracking, cyclization, cyclooligomerization, dehalogenation, dimerization, epoxidation, esterification, exchange, Fischer-Tropsch, halogenation, hydrohalogenation, homologation, hydration, dehydration, hydrogenation, dehydrogenation, hydrocarboxylation, hydroformylation, hydrogenolysis, hydrometallation, hydrosilation, hydrolysis, hydrotreating (HDS/HDN), isomerization, methylation, demethylation, metathesis, nitration, polymerization, reduction, reformation, reverse water gas shift, Sabatier, sulfonation, telomerization, transesterification, trimerization, and water gas shift; and forming at least one product. 4. The method of claim 3 wherein the microchannel has at least two inlets. 5. The method of claim 3 wherein heat is transferred between the microchannel and an adjacent heat exchanger. 6. A method of conducting a reaction, comprising: flowing at least one reactant into a microchannel through a microchannel inlet; wherein the microchannel comprises a center and a microchannel wall; wherein the microchannel contains one catalyst that is a graded catalyst that has a higher concentration of catalytically active material in the catalyst nearer the microchannel wall than the concentration of the catalytically active material in the catalyst nearer the center of the microchannel; and wherein the microchannel wall is adjacent to a heat exchanger; reacting the at least one reactant in the presence of the graded catalyst within the microchannel; wherein the reactant, or reactants, and catalyst are selected such that the step of reacting is selected from the group consisting of: acetylation, addition reactions, alkylation, dealkylation, hydrodealkylation, reductive alkylation, amination, ammoxidation, ammonia synthesis, aromatization, arylation, autothermal reforming, carbonylation, decarbonylation, reductive carbonylation, carboxylation, reductive carboxylation, reductive coupling, condensation, cracking, hydrocracking, cyclization, cyclooligomerization, dehalogenation, dimerization, epoxidation, esterification, exchange, Fischer-Tropsch, halogenation, hydrohalogenation, homologation, hydration, dehydration, hydrogenation, dehydrogenation, hydrocarboxylation, hydroformylation, hydrogenolysis, hydrometallation, hydrosilation, hydrolysis, hydrotreating (HDS/HDN), isomerization, methylation, demethylation, metathesis, nitration, polymerization, reduction, reformation, reverse water gas shift, Sabatier, sulfonation, telomerization, transesterification, trimerization, and water gas shift; simultaneous with the step of reacting, transferring heat between the microchannel and the heat exchanger; and forming at least one product. 7. The method of claim 6 wherein the heat exchanger is a microchannel heat exchanger. 8. A method of conducting a reaction, comprising: flowing at least one reactant into a first reaction microchannel; wherein a catalyst is disposed in the first reaction microchannel; reacting the at least one reactant in the presence of the graded catalyst within the first reaction microchannel; wherein the reactant, or reactants, and catalyst are selected such that the step of reacting is selected from the group consisting of: acetylation, addition reactions, alkylation, dealkylation, hydrodealkylation, reductive alkylation, amination, ammoxidation, ammonia synthesis, aromatization, arylation, autothermal reforming, carbonylation, decarbonylation, reductive carbonylation, carboxylation, reductive carboxylation, reductive coupling, condensation, cracking, hydrocracking, cyclization, cyclooligomerization, dehalogenation, dimerization, epoxidation, esterification, exchange, Fischer-Tropsch, halogenation, hydrohalogenation, homologation, hydration, dehydration, hydrogenation, dehydrogenation, hydrocarboxylation, hydroformylation, hydrogenolysis, hydrometallation, hydrosilation, hydrolysis, hydrotreating (HDS/HDN), isomerization, methylation, demethylation, metathesis, nitration, polymerization, reduction, reformation, reverse water gas shift, Sabatier, sulfonation, telomerization, transesterification, trimerization, and water gas shift; wherein the catalyst is a graded catalyst that has a higher concentration of catalytically active material in the catalyst nearer the microchannel wall than the concentration of the catalytically active material in the catalyst nearer the center of the microchannel; exchanging heat between the first reaction microchannel and an adjacent, second reaction microchannel; wherein one of the first or second reaction channels comprises an exothermic reaction and the other of the reaction channels comprises an endothermic reaction; and forming at least one first product in the first reaction microchannel and forming at least one second product in the second reaction microchannel. 9. The method of claim 8 wherein heat is exchanged while the step of reacting is occurring in the microchannel. 10. The method of claim 8 wherein the second reaction microchannel provides heat for startup. 11. The method of claim 8 wherein the second reaction microchannel comprises a graded catalyst. 12. The method of claim 8 wherein the step of reacting comprises a reaction selected from the group consisting of Fischer-Tropsch, methanol synthesis, and partial oxidation. 13. A method of conducting a reaction, comprising: flowing at least one reactant into a microchannel; wherein a catalyst is disposed in the microchannel; wherein the catalyst consists of a graded catalyst that has a higher concentration of catalytically active material in the catalyst nearer the microchannel wall than the concentration of the catalytically active material in the catalyst nearer the center of the microchannel; a step of reacting the at least one reactant in the presence of the graded catalyst within the microchannel; wherein the reactant, or reactants, and catalyst are selected such that the step of reacting is selected from the group consisting of: acetylation, addition reactions, alkylation, dealkylation, hydrodealkylation, reductive alkylation, amination, ammoxidation, ammonia synthesis, aromatization, arylation, autothermal reforming, carbonylation, decarbonylation, reductive carbonylation, carboxylation, reductive carboxylation, reductive coupling, condensation, cracking, hydrocracking, cyclization, cyclooligomerization, dehalogenation, dimerization, epoxidation, esterification, exchange, Fischer-Tropsch, halogenation, hydrohalogenation, homologation, hydration, dehydration, hydrogenation, dehydrogenation, hydrocarboxylation, hydroformylation, hydrogenolysis, hydrometallation, hydrosilation, hydrolysis, hydrotreating (HDS/HDN), isomerization, methylation, demethylation, metathesis, nitration, polymerization, reduction, reformation, reverse water gas shift, Sabatier, sulfonation, telomerization, transesterification, trimerization, and water gas shift; and forming at least one product. 14. The method of claim 13 wherein the step of reacting comprises a reforming reaction and the graded catalyst comprises comprises at least one metal selected from the group consisting of Pt, Ni and Rh. 15. The method of claim 13 wherein the step of reacting comprises a dehydrogenation reaction and the graded catalyst comprises Pd and Zn. 16. A method of conducting a reaction, comprising: flowing at least one reactant into a microchannel; wherein a catalyst is disposed in the microchannel; wherein the graded catalyst has a varying thermal conductivity such that the thermal conductivity in one part of the graded catalyst is at least 25% higher than in another part of the graded catalyst; a step of reacting the at least one reactant in the presence of the graded catalyst within the microchannel; wherein the reactant, or reactants, and catalyst are selected such that the step of reacting is selected from the group consisting of: acetylation, addition reactions, alkylation, dealkylation, hydrodealkylation, reductive alkylation, amination, ammoxidation, ammonia synthesis, aromatization, arylation, carbonylation, decarbonylation, reductive carbonylation, carboxylation, reductive carboxylation, reductive coupling, condensation, cracking, hydrocracking, cyclization, cyclooligomerization, dehalogenation, dimerization, epoxidation, esterification, exchange, Fischer-Tropsch, halogenation, hydrohalogenation, homologation, hydration, dehydration, hydrogenation, hydrocarboxylation, hydroformylation, hydrogenolysis, hydrometallation, hydrosilation, hydrolysis, hydrotreating (HDS/HDN), isomerization, methylation, demethylation, metathesis, nitration, polymerization, hydrocarbon reforming, reverse water gas shift, Sabatier, sulfonation, telomerization, transesterification, trimerization, and water gas shift; and forming at least one product. 17. The method of claim 16 wherein the step of reacting comprises a Fischer-Tropsch reaction and the graded catalyst comprises at least one metal selected from the group consisting of Co, Ru, Fe, Rh, and Ni. 18. The method of claim 16 wherein the step of reacting comprises a hydrogenation reaction and the graded catalyst comprises at least one metal selected from the group consisting of Co, Pd, Pt, and Ni. 19. The method of claim 16 wherein the step of reacting comprises a hydrogenolysis of an alcohol or ether and the graded catalyst comprises at least one metal selected from the group consisting of Pd, Pt, and Ni. 20. The method of claim 16 wherein the step of reacting comprises a dehydration of an alcohol and the graded catalyst comprises at least one metal selected from the group consisting of Cu, Pt, and Ni. 21. The method of claim 16 wherein the step of reacting comprises a water-gas shift reaction and the graded catalyst comprises at least one metal selected from the group consisting of Fe, CuZn, CoMo, and Ru. 22. The method of claim 16 wherein the step of reacting comprises ammonia synthesis and the graded catalyst comprises Fe. 23. The method of claim 16 wherein the step of reacting comprises a hydrocracking reaction and the graded catalyst comprises at least one metal selected from the group consisting of Pd and Ni-Mo. 24. The method of claim 16 wherein the step of reacting comprises a hydrodesulfurization reaction and the graded catalyst comprises at least one metal selected from the group consisting of Co-Mo and Ni-Mo. 25. The method of claim 6 wherein the catalyst further comprises a variation in a physical property as a function of distance through the catalyst. 26. The method of claim 6 wherein the graded catalyst has a varying thermal conductivity such that the thermal conductivity in one part of the graded catalyst is at least 25% higher than in another part of the graded catalyst. 27. The method of claim 3 wherein the graded catalyst has a varying thermal conductivity such that the thermal conductivity in one part of the graded catalyst is at least 200% higher than in another part of the graded catalyst. 28. The method of claim 1 wherein surface area varies as a function of distance through the catalyst. 29. The method of claim 25 wherein surface area varies as a function of distance through the catalyst. 30. The method of claim 28 wherein the graded catalyst gradually changes its surface area as a function of distance. 31. The method of claim 6 wherein the graded catalyst comprises at least a portion of at least one wall of a bulk flow path through the microchannel. 32. A method of conducting a reaction, comprising: flowing at least one reactant into a microchannel; wherein the microchannel comprises a graded catalyst wherein the graded catalyst comprises at least a portion of at least one wall of a bulk flow path through the microchannel; reacting the at least one reactant in the presence of the graded catalyst within the microchannel; wherein the reactant, or reactants, and catalyst are selected such that the step of reacting is selected from the group consisting of: acetylation, addition reactions, ailcylation, dealkylation, hydrodealkylation, reductive alkylation, amination, ammoxidation, ammonia synthesis, aromatization, arylation, autothermal reforming, carbonylation, decarbonylation, reductive carbonylation, carboxylation, reductive carboxylation, reductive coupling, condensation, cracking, hydrocracking, cyclization, cyclooligomerization, dehalogenation, dimerization, epoxidation, esterification, exchange, Fischer-Tropsch, halogenation, hydrohalogenation, homologation, hydration, dehydration, hydrogenation, dehydrogenation, hydrocarboxylation, hydroformylation, hydrogenolysis, hydrometallation, hydrosilation, hydrolysis, hydrotreating (HDS/HDN), isomerization, methylation, demethylation, metathesis, nitration, polymerization, reduction, reformation, reverse water gas shift, Sabatier, sulfonation, telomerization, transesterification, trimerization, and water gas shift; wherein the physical form of the catalyst varies over the length of the microchannel and forming at least one product. 33. A method of conducting a reaction, comprising: flowing at least one reactant into a microchannel; wherein the microchannel comprises a graded catalyst; reacting the at least one reactant in the presence of the graded catalyst within the microchannel; wherein the reactant, or reactants, and catalyst are selected such that the step of reacting is selected from the group consisting of: acetylation, addition reactions, alkylation, dealkylation, hydrodealkylation, reductive alkylation, amination, ammoxidation, ammonia synthesis, aromatization, arylation, autothermal reforming, carbonylation, decarbonylation, reductive carbonylation, carboxylation, reductive carboxylation, reductive coupling, condensation, cracking, hydrocracking, cyclization, cyclooligomerization, dehalogenation, dimerization, epoxidation, esterification, exchange, Fischer-Tropsch, halogenation, hydrohalogenation, homologation, hydration, dehydration, hydrogenation, dehydrogenation, hydrocarboxylation, hydroformylation, hydrogenolysis, hydrometallation, hydrosilation, hydrolysis, hydrotreating (HDS/HDN), isomerization, methylation, demethylation, metathesis, nitration, polymerization, reduction, reformation, reverse water gas shift, Sabatier, sulfonation, telomerization, transesterification, trimerization, and water gas shift; wherein the physical form of the catalyst varies over the width of the microchannel; and forming at least one product. 34. The method of claim 1 wherein the graded catalyst substantially fills a cross section of the microchannel. 35. The method of claim 6 wherein the graded catalyst comprises catalyst particles have an aspect ratio greater than 3 and wherein a majority of these particles are oriented with the particles' ends having a greater amount of catalyst near a microchannel wall.
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