Flow Distribution Channels To Control Flow in Process Channels

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.

1 . A method of fluid processing, comprising: 
 passing a process stream into a manifold;    wherein the manifold is connected to at least a first flow distribution channel (FDC) and a second FDC;    wherein each FDC comprises a series of turns, comprising at least four turns that are 90° or less, or comprising at least two turns that are greater than 90°; and    wherein the first FDC channel connects the manifold to a first process channel;    wherein the second FDC channel connects the manifold to a second process channel; and wherein the portion of the process stream that flows through the first FDC connects with only one process channel and does not connect with any other FDC so that all of the portion of the process stream that enters the first FDC flows into the first process channel; and    conducting a unit operation in the first and second process channels.    
   
   
       2 . The method of  claim 1  wherein each FDC comprises at least three turns and each of said three turns has an angle of at least 135°.  
   
   
       3 . The method of  claim 1  comprising conducting a step of partially boiling the process stream as it passes through the first process channel.  
   
   
       4 . The method of  claim 3  where 0.5 to 50% of the process stream entering the first process channel undergoes boiling in the first process channel.  
   
   
       5 . The method of  claim 1  wherein the process stream in the process channel comprises an emulsion, a dispersion, or a non-Newtonian fluid.  
   
   
       6 . The method of  claim 5  wherein the first process channel has channel walls that comprise orifices, and wherein the first process channel comprises a first fluid comprising a first phase and a second fluid, which is immiscible in the first fluid, passes through the orifices into the first fluid to form an emulsion.  
   
   
       7 . The method of  claim 5  wherein flow in the first FDC is Newtonian and wherein flow in the first process channel is non-Newtonian.  
   
   
       8 . The method of  claim 1  wherein the first and second FDCs have the same length.  
   
   
       9 . A method of distributing flow from a manifold into plural process channels, comprising: 
 passing a process stream into a manifold;    wherein the manifold is connected to at least a first FDC and a second FDC;    wherein each FDC comprises a series of turns, comprising at least four turns that are 90° or less, or comprising at least two turns that are greater than 90°; and    wherein the first FDC channel connects the manifold to a first process channel;    wherein the second FDC channel connects the manifold to a second process channel; 
 and wherein the first FDC channel is on the same plane as the first process channel, and wherein the first FDC has a cross-sectional area and the cross-sectional area of the FDC at all points is less than the cross-sectional area of the first process channel.  
   
   
   
       10 . The method of  claim 9  wherein the first FDC channel is on the same plane as the first process channel and the manifold.  
   
   
       11 . A microchannel device, comprising: 
 a manifold;    wherein the manifold is connected to at least a first FDC and a second FDC;    wherein each FDC comprises a series of turns, comprising at least four turns that are 90° or less,    or comprising at least two turns that are greater than 90°; and    wherein the first FDC channel connects the manifold to a first process channel;    wherein the second FDC channel connects the manifold to a second process channel; 
 and wherein the first FDC connects with only one process channel and does not connect with any other FDC so that all of the portion of the process stream that enters the first FDC flows into the first process channel.  
   
   
   
       12 . A microchannel device, comprising: 
 a manifold;    wherein the manifold is connected to at least a first FDC and a second FDC;    wherein each FDC comprises a series of turns, comprising at least four turns that are 90° or less, or comprising at least two turns that are greater than 90°; and    wherein the first FDC channel connects the manifold to a first process channel;    wherein the second FDC channel connects the manifold to a second process channel; 
 and wherein the first FDC channel is on the same plane as the first process channel.  
   
   
   
       13 . A process of combining fluids, comprising: 
 passing a first fluid through a process channel;    passing a second fluid through a FDC and into the process channel where the first and second fluids combine, where the FDC comprises a series of turns, comprising at least four turns that are 90° or less, or comprising at least two turns that are greater than 90°;    wherein the first and second fluids are different.    
   
   
       14 . The process of  claim 13  wherein the mass flow rate of the first fluid into the process channel is 5% or less than the flow rate of the second fluid in the process channel.  
   
   
       15 . The process of  claim 13  wherein the FDC comprises at least two turns that have different angles.  
   
   
       16 . The process of  claim 13  where the process channel is straight and wherein flow in the process channel is non-Newtonian.  
   
   
       17 . Apparatus for combining fluids, comprising: 
 a process channel;    an added fluid channel;    a FDC connecting the added fluid channel to the process channel, where the FDC comprises a series of turns, comprising at least four turns that are 90° or less, or comprising at least two turns that are greater than 90°.    
   
   
       18 . The apparatus of  claim 17  comprising plural process channels connected to one added fluid channel via plural FDCs, wherein each FDC comprises a series of turns, comprising at least four turns that are 90° or less, or comprising at least two turns that are greater than 90°.  
   
   
       19 . A method of fluid processing, comprising: 
 passing a process stream into a manifold;    wherein the manifold is connected to at least a first flow distribution channel (FDC) and a second FDC;    wherein the first FDC comprises a first portion having a single channel, a second portion that is connected to the first portion at one end and a first process channel at another end, and a third portion that is connected to the first portion at one end and a second process channel at another end;    wherein the second FDC comprises a first channel portion having a single flow path, a second channel portion that is connected to the first channel portion at one end and a third process channel at another end, and a third channel portion that is connected to the first channel portion at one end and a fourth process channel at another end;    wherein each FDC portion comprises a series of turns, comprising at least four turns that are 90° or less, or comprising at least two turns that are greater than 90°; and    conducting a unit operation in the first, second, third and fourth process channels.