Methods of Making Devices By Stacking Sheets and Processes of Conducting Unit Operations Using Such Devices

Abstract

New designs, methods and processes are described that in which laminated devices and configured in a style named the “ortho” style. To form a device in the ortho style, plates or sheets are machined to have apertures and then stacked together such that the apertures connect and fluid can flow through the device in a direction that is substantially parallel to the direction of sheet thickness. Various laminated devices and processes using them are also described. For example, devices in which non-rectangular microchannels conform around reaction chambers or other bodies that need to be heated or cooled, are described. Features that separate or trip boundary layer and enhance heat transfer are also described.

1 - 37 . (canceled) 
     
     
         38 . A laminated device, comprising: a first set of microchannels wherein each microchannel has an inlet and an outlet, a header connected to the inlets of the first set of microchannels; a footer connected to the outlets of the first set of microchannels; and comprising a header or footer structure, wherein the header has a surface that curves toward at least a portion of the inlets of the first set of microchannels, or the footer has a surface that curves toward at least a portion of the outlets of the first set of microchannels, or the footer comprises a roof, located on a side of the footer opposite the side that is connected to the outlets of the first set of microchannels, and the roof is sloped relative to the outlets of the first set of microchannels. 
     
     
         39 . The device of  claim 38  further comprising a second set of microchannels that are adjacent to and in thermal contact with the first set of microchannels. 
     
     
         40 . The device of  claim 39  wherein the device comprises a condenser or a vaporizer. 
     
     
         41 . The device of  claim 38  wherein the header has a surface that curves toward at least a portion of the inlets of the first set of microchannels, or the footer has a surface that curves toward at least a portion of the outlets of the first set of microchannels, and further comprising a flow path that is adjacent to either the header or the footer, wherein the flow path is separated from the header or the footer by a curved wall that has one surface facing the microchannels and one surface that faces the flow path. 
     
     
         42 . The device of  claim 41  wherein both the header and the footer have a surface that curves toward the microchannels. 
     
     
         43 . The device of  claim 39  wherein the device is a component of a larger device. 
     
     
         44 . The laminated device of  claim 40 , wherein the device comprises a vaporizer, wherein the footer comprises a roof, and the roof has at least two sides that converge to form an apex. 
     
     
         45 . The device of  claim 44  wherein the roof comprises multiple outlets. 
     
     
         46 . The device of  claim 39  formed by a method comprising stacking shims such that shim thickness is substantially parallel to fluid flow through the device, as flow will occur during normal operation of the device is in operation. 
     
     
         47 . Apparatus for vaporizing water comprising: an inlet leading to a first set of microchannels for a liquid to flow into; a second set of microchannels for a fluid to flow through; wherein the first set of microchannels is adjacent to the second set of microchannels; and wherein the vaporizer possesses a performance characteristic such that, when tested by flowing air at 247 SLPM and 279° C. as a heat transfer fluid and water at 20 mL/min and 280 psig, pressure drop through the device for the partially boiling water increases by less than 5 psig. 
     
     
         48 . A laminated device capable of operating with fluids of different pressures, comprising: at least one microchannel; and at least one other chamber; wherein the at least one microchannel is adjacent to the at least one chamber; and wherein the at least microchannel and the at least one chamber are separated by a wall having a thickness of 5 mm or less; wherein the laminated device is characterized by a pressure resistance such that a first fluid stream 279° C. and 8 psig is passed through the at least one microchannel, and a second fluid stream at 210° C. and 280 psig is passed through the at least one other chamber for 1000 hours during which there are 10 thermal cycles to ambient temperature of the entire device; and wherein after 1000 hours operation, each fluid flow path is pressurized to 50 psig and held for 2 hours; and wherein the pressure remains substantially constant as measured by a leak rate of less than 10 −6  standard cubic centimeters per second of helium to the environment; and further wherein the at least one other chamber is pressurized to 50 psig, leaving the at least one microchannel open to atmosphere, and held for 2 hours; and wherein the pressure in the at least one other chamber remains constant as measured by a leak rate of less than 10 −6  standard cubic centimeters per second of helium indicating minimal internal leak paths. 
     
     
         49 . A method of conducting a process with a two phase mixture in a microchannel device, comprising: passing a fluid into the device of  claim 47 . 
     
     
         50 . A method of vaporizing water comprising the steps of: passing a liquid into the first set of microchannels in the apparatus of  claim 52 ; and simultaneously, passing a fluid into the second set of microchannels in the apparatus of  claim 52 ; wherein the fluid is at a temperature sufficient to vaporize at least a portion of the liquid. 
     
     
         51 . The method of  claim 50  wherein the liquid and the fluid flow in opposite directions. 
     
     
         52 . Apparatus for vaporizing water comprising: an inlet leading to a first set of microchannels for a liquid to flow into; a second set of microchannels for a fluid to flow through; wherein the first set of microchannels is adjacent to the second set of microchannels; and wherein the vaporizer possesses a performance characteristic such that, when tested with 1.5 ppm TDS water of which the total solids comprises at least 7% Ca, 15% Mg and 2% Si is passed through the first set of microchannels at 280 psig, a 210° C. inlet temperature, and a flowrate of 20 mL/min and a flow air of air at 8 psig, 279° C. and a flowrate of 247 SLPM, over 40% of the water boils with a pressure drop rise of less than 5 psig through the first set of microchannels after 1000 hours of operation. 
     
     
         53 . The apparatus of  claim 52  wherein the vaporizer possesses a performance characteristic such that, when tested with 1.5 ppm TDS water of which the total solids comprises at least 7% Ca, 15% Mg and 2% Si is passed through the first set of microchannels at 280 psig, a 210° C. inlet temperature, and a flowrate of 20 mL/min and a flow air of air at 8 psig, 279° C. and a flowrate of 247 SLPM, over 40% of the water boils with a pressure drop rise of less than 5 psig through the first set of microchannels after 5000 hours of operation. 
     
     
         54 . The vaporizer of  claim 52  comprising at least two sets of microchannels for a liquid to flow into; and further comprising at least two sets of microchannels for a fluid to flow through; wherein each set of microchannels is arranged in a row;
 and wherein the sets of microchannels for a liquid to flow into and the sets of microchannels for a fluid to flow through are arranged in alternating rows. 
 
     
     
         55 . The vaporizer of  claim 54  wherein each row comprises at least three microchannels. 
     
     
         56 - 63 . (canceled)