Microreactors and methods for generating hydrogen peroxide

Abstract

Microreactors ( 10 ) and methods for generating hydrogen peroxide are disclosed. More specifically, microreactors ( 10 ) and methods are provided for the batchwise generation of hydrogen peroxide in which respective hydrogen and oxygen electrolysis chambers, and a hydrogen peroxide reaction chamber is fluid-connected to and positioned physically between, the electrolysis chambers. In specially preferred embodiments, the hydrogen peroxide microreactor ( 10 ) of the present invention will be in the form of a silicon chip reactor body having a pair of electrolysis channels ( 14 - 1, 14 - 2 ), reactant channel ( 14 - 3 ) positioned between the electrolysis channels, and at least one (preferably several) connector channel(s) ( 14 - 4 ) which fluid-connect(s) the pair of electrolysis channels ( 14 - 1, 14 - 2 ) with said reactant channel ( 14 - 3 ). A pair of electrodes ( 16 - 1, 16 - 2 ) is provided so that each is in operative association with a respective one of the electrolysis channels ( 14 - 1, 14 - 2 ). A catalyst for forming hydrogen peroxide is also provided so as to be in operative association with the reactant channel ( 14 - 3 ).

1 . A hydrogen peroxide microreactor comprising a silicon chip reactor body having a pair of electrolysis channels, a reaction channel positioned between said electrolysis channels, and at least one connector channel which fluid-connects said pair of electrolysis channels with said reaction channel, a pair of electrodes each in operative association with a respective one of said electrolysis channels, and a catalyst for forming hydrogen peroxide in operative association with the reaction channel.  
   
   
       2 . The microreactor according to  claim 1 , wherein said reactor body comprises top and bottom silicon chips, wherein said electrolysis channels, said reaction channel and said at least one connector channel are etched into said bottom silicon chip.  
   
   
       3 . The microreactor according to  claim 1 , further comprising a plurality of ports in fluid communication with said electrolysis and reaction channels.  
   
   
       4 . The microreactor according to  claim 2 , wherein said electrolysis and reaction channels are elongate linear channels etched in said bottom silicon chip.  
   
   
       5 . The microreactor according to  claim 4 , wherein said at least one connector channel is an elongate linear channel etched in said bottom silicon chip substantially transverse to said electrolysis and reaction channels.  
   
   
       6 . The microreactor as in  claim 5 , wherein said reaction channel is positioned closer to one of said electrolysis channels as compared to the other of said electrolysis channels.  
   
   
       7 . The microreactor as in  claim 6 , wherein the reaction channel is positioned about one-third of the total distance between said electrolysis channels from said one electrolysis channels.  
   
   
       8 . The microreactor as in  claim 5 , wherein said electrolysis and reaction channels are substantially V-shaped.  
   
   
       9 . The microreactor as in  claim 1 , wherein said electrodes and said catalyst are in the form of strips operatively associated with said electrolysis channels and said reaction channel, respectively.  
   
   
       10 . A method for making hydrogen peroxide comprising: 
 (i) providing a sealed water-filled microreactor formed of a silicon reactor body having a pair of electrolysis channels, a reaction channel positioned between said electrolysis channels, and at least one connector channel which fluid-connects said pair of electrolysis channels with said reaction channel, a pair of electrodes each in operative association with a respective one of said electrolysis channels, and a catalyst for forming hydrogen peroxide in operative association with the reaction channel;    (ii) applying an electrical potential to said electrodes so as to generate hydrogen from an anode thereof, and oxygen from a cathode thereof;    (iii) allowing the hydrogen and oxygen generated according to step (ii) to diffuse into the reaction chamber to cause a catalytic reaction therebetween to form hydrogen peroxide; and    (iv) withdrawing the hydrogen peroxide from the reaction chamber.    
   
   
       11 . The method of  claim 10 , wherein step (iii) is practiced at a pressure of about 1000 psi or greater.  
   
   
       12 . A method of making a microreactor for generating hydrogen peroxide, comprising: 
 (a) etching into a silicon chip a pair of electrolysis channels, a reaction channel positioned between said electrolysis channels, and at least one connector channel which fluid-connects said pair of electrolysis channels with said reaction channel;    (b) providing a pair of electrodes each in operative association with a respective one of said electrolysis channels, and a catalyst for forming hydrogen peroxide in operative association with the reaction channel.    
   
   
       13 . The method according to  claim 12 , wherein said reactor body comprises top and bottom silicon chips, and wherein step (a) is practiced by etching said electrolysis channels, said reaction channel and said at least one connector channel into said bottom silicon chip.  
   
   
       14 . The method according to  claim 13 , further comprising etching a plurality of ports in said top silicon chip which are in fluid communication with said electrolysis and reaction channels etched into said bottom silicon chip.  
   
   
       15 . The method according to  claim 13 , wherein step (a) is practiced so as to etch aid electrolysis and reaction channels in the form of elongate linear channels in said bottom silicon chip.  
   
   
       16 . The method according to  claim 15 , wherein step (a) is practiced so as to etch said at least one connector channel in the form of an elongate linear channel in said bottom silicon chip substantially transverse to said electrolysis and reaction channels.  
   
   
       17 . The method as in  claim 16 , wherein step (a) is practiced so that said reaction channel is positioned closer to one of said electrolysis channels as compared to the other of said electrolysis channels.  
   
   
       18 . The method according to  claim 17 , wherein step (a) is practiced so as that the reaction channel is positioned about one-third of the total distance between said electrolysis channels from said one electrolysis channels.  
   
   
       19 . The method according to  claim 12 , wherein step (a) is practice such that said electrolysis and reaction channels are substantially V-shaped.  
   
   
       20 . The method according to  claim 12 , comprising providing said electrodes and said catalyst are in the form of strips operatively associated with said electrolysis channels and said reaction channel, respectively.