Methods for using parallel flow reactor having improved thermal control

Abstract

Parallel flow chemical processing systems, such as parallel flow chemical reaction systems are disclosed. These systems are adapted to simultaneously and independently vary temperature between separate flow channels, preferably by employing separate, individual heating elements in thermal communication with each of four or more parallel flow reactors. The flow reactors are preferably isolated from each other using a thermal isolation system comprising fluid-based heat exchange. In preferred embodiments, the axial heat flux can be fixedly or controllably varied.

1 . A parallel flow reaction system for effecting four or more simultaneous reactions in four or more reaction channels, the reaction system comprising 
 four or more reactors configured and arranged in an array with a center-to-center distance between adjacent reactors of not more than about 10 times the diameter of the reactor for reactors with circular cross-sections, or not more than about 10 times the length of a chord intersecting the center of the reactor for reactors having a non-circular cross-section, each of the four or more reactors comprising a surface defining a reaction cavity for carrying out a chemical reaction, an inlet port in fluid communication with the reaction cavity, and an outlet port in fluid communication with the reaction cavity, the four or more reactors being adapted for effecting a chemical reaction at reaction temperatures of greater than about 100° C.,    a fluid distribution system for simultaneously supplying one or more reactants to the reaction cavity of each of the four or more reactors, and for discharging a reactor effluent from the outlet port of each such reaction cavity to one or more effluent sinks, and    a temperature control system comprising four or more individually-controllable heating elements in thermal communication with the four or more reactors, respectively, for simultaneously and individually controlling the temperature of each of the four or more reactors, the temperature control system being adapted to provide individually variable temperature differences of at least about 10° C. as compared between four or more spatially adjacent reactors.    
     
     
         2 . The reaction system of  claim 1  wherein each of the four or more heating elements provides an axially-varying heat flux to the reaction cavity of its respective reactor.  
     
     
         3 . A parallel flow reaction system for effecting four or more simultaneous reactions in four or more reaction channels, the reaction system comprising 
 four or more reactors, each of the four or more reactors comprising a surface defining a reaction cavity for carrying out a chemical reaction, an inlet port in fluid communication with the reaction cavity, and an outlet port in fluid communication with the reaction cavity, the four or more reactors being adapted for effecting a chemical reaction at reaction temperatures of greater than about 100° C.,    a fluid distribution system for simultaneously supplying one or more reactants to the reaction cavity of each of the four or more reactors, and for discharging a reactor effluent from the outlet port of each such reaction cavity to one or more effluent sinks, and    a temperature control system comprising four or more individually-controllable heating elements in thermal communication with the four or more reactors, respectively, for simultaneously and individually controlling the temperature of each of the four or more reactors, each of the four or more heating elements providing an axially-varying heat flux to the reaction cavity of its respective reactor.    
     
     
         4 . The reaction system of claims  1  or  3  wherein the temperature control system is adapted to provide individually variable temperature differences of at least about 50° C. as compared between four or more spatially adjacent reactors.  
     
     
         5 . The reaction system of claims  1  or  3  wherein the temperature control system is adapted to provide individually variable temperature differences of at least about 100° C. as compared between four or more spatially adjacent reactors.  
     
     
         6 . The reaction system of claims  1  or  3  wherein the four or four or more heating elements are resistive heating elements.  
     
     
         7 . The reaction system of claims  1  or  3  wherein the volume of the reaction cavity of the four or more reactors is not more than about 1 ml.  
     
     
         8 . The reaction system of claims  1  or  3  wherein the four or more reactors comprise an array of four or more reactors configured and arranged such that the spatial density of reactors in a two-dimensional array is not less than about 1 reactor/10 cm 2 , or in a linear or curvilinear array is not less than about 1 reactor/3 cm.  
     
     
         9 . The reaction system of claims  1  or  3  wherein the four or more reactors are configured and arranged in an array having at least one reactor that is about equidistant from at least three other reactors.  
     
     
         10 . The reaction system of claims  1  or  3  wherein the four or more reactors each have a reaction cavity volume of not more than about 1 ml, the four or more reactors being configured and arranged in an array having at least one reactor that is about equidistant from at least three other reactors such that the spatial density of four or more reactors in the array is not less than about 1 reactor/10 cm 2 , and the temperature control system is adapted to provide individually variable temperature differences of at least about 50° C. as compared between four or more spatially adjacent reactors.  
     
     
         11 . The reaction system of  claim 10  wherein the four or more reactors are configured and arranged such that the spatial density of four or more reactors in the array is not less than about 1 reactor/1 cm 2 .  
     
     
         12 . The reaction system of claims  1  or  3  wherein the four or more reactors comprise elongated reaction vessels.  
     
     
         13 . The reaction system of claims  1  or  3  wherein the four or more reactors are elongated reaction vessels having a first end section substantially adjacent the inlet port, a second end section substantially adjacent the outlet port, and a midsection between the first end section and the second end section, the midsection including a portion of the reaction cavity adapted to contain a catalyst and defining a reaction zone.  
     
     
         14 . The reaction system of claims  2  or  3  wherein the heating elements associated with the four or more reactors are adapted to provide a substantially uniform temperature profile along the direction of reactant flow through a reaction zone of the reactors.  
     
     
         15 . The reaction of  claim 14  wherein the heating elements associated with the four or more reactors are adapted to provide a temperature profile that varies by less than about 5% through the reaction zone of the reactors.