Integrated microchannel synthesis and separation

Abstract

An integrated microchannel reactor and heat exchanger comprising: (a) a waveform sandwiched between opposing shim sheets and mounted to the shim sheets to form a series of microchannels, where each microchannel includes a pair of substantially straight side walls, and a top wall formed by at least one of the opposing shim sheets, and (b) a first set of microchannels in thermal communication with the waveform, where the waveform has an aspect ratio greater than two.

What is claimed is: 
     
         1 . A process for the formation of methanol, the process comprising the steps of:
 (a) inputting a feed stream comprising carbon containing molecules and hydrogen containing molecules to a microchannel reactor;   (b) reacting a portion of the carbon containing molecules with the hydrogen containing molecules within the microchannel reactor to form methanol molecules flowing in a process stream;   (c) removing at least some of the formed methanol molecules from the process stream; and   (d) reacting a further portion the carbon containing molecules with the hydrogen containing molecules to form methanol molecules flowing in the process stream;   wherein greater than ninety percent of the carbon containing molecules have been reacted to form methanol.   
     
     
         2 . The process of  claim 1 , further comprising:
 (a2) changing at least one of temperature and pressure of the feed steam prior to step (b).   
     
     
         3 . The process of  claim 1 , further comprising:
 (b2) changing at least one of temperature and pressure of the process steam prior to step (c).   
     
     
         4 . The process of  claim 1 , further comprising:
 (c2) changing at least one of temperature and pressure of the process stream after step (c) and before step (d).   
     
     
         5 . The process of  claim 1 , further comprising:
 (b2) recouping at least some of the energy generated within the microchannel reactor by thermal communication with a lower energy fluid stream within the microchannel reactor.   
     
     
         6 . The process of  claim 1 , further comprising:
 (b2) changing at least one of temperature and pressure of the process steam prior to step (c); and   (c2) changing at least one of temperature and pressure of the process stream after step (c) and before step (d);   wherein step (b2) is carried out in a first heat exchanger integrated with the microchannel reactor; and   wherein step (c2) is carried out in a second heat exchanger integrated with the microchannel reactor.   
     
     
         7 . The process of  claim 6 , further comprising:
 delivering a heat transfer fluid medium into thermal communication with the process stream flowing through at least one of the first heat exchanger and the second heat exchanger.   
     
     
         8 . The process of  claim 1 , further comprising:
 (b2) changing at least one of temperature and pressure of the process steam prior to step (c); and   (c2) changing at least one of temperature and pressure of the process stream after step (c) and before step (d);   wherein step (b2) and step (c2) are carried out in a heat exchanger integrated with the microchannel reactor.   
     
     
         9 . The process of  claim 8 , further comprising:
 delivering a heat transfer fluid medium into thermal communication with the process stream flowing through the heat exchanger.   
     
     
         10 . The process of  claim 1 , further comprising:
 (b2) directing the process stream into a microchannel separation unit operation; wherein:
 step (b) includes distributing the feed stream among a plurality of microchannels to comprise a plurality of sub-process streams, and 
 step (b2) includes the step of maintaining separability of the sub-process streams upon entry into the microchannel separation unit operation. 
   
     
     
         11 . The process of  claim 1 , further comprising:
 (a2) distributing the feed stream among a plurality of microchannels of the microchannel reactor that are operative to form a plurality of sub-process streams directly conveying the feed steam to at least one unit operation.   
     
     
         12 . The process of  claim 11 , wherein the unit operation includes at least one of a chemical reactor, a chemical separator, a heat exchanger, a compressor, an expander, a vaporizer, a condenser, a phase separator, and a mixer. 
     
     
         13 . The process of  claim 1 , wherein:
 the microchannel reactor of step (a) includes two separate microchannel reactors;   the feed stream of step (a) is distributed among the two separate microchannel reactors;   the process stream of step (b) comprises each outlet process stream from the two separate microchannel reactors;   a first outlet process stream from one of the two separate microchannel reactors is fed to a downstream heat exchanger;   a second outlet process stream from the other of the two separate microchannel reactors is fed to the downstream heat exchanger;   in step (c) the first outlet process stream is cooled to a lower temperature within the heat exchanger to liquefy at least one of the methanol molecules and forming a gaseous phase process stream lean in methanol molecules; and   the second outlet process stream is in thermal communication with the gaseous phase process stream and is operative to elevate the temperature of the gaseous phase process stream.   
     
     
         14 . The process of  claim 1 , further comprising:
 (b2) performing a heat exchange operation between the process stream and a cooling fluid stream flowing through the microchannel reactor, where the process stream is not in fluid communication with the cooling fluid stream;   wherein:
 step (b2) includes distributing the process stream among a plurality of microchannels to comprise a plurality of sub-process streams, and 
 step (b2) includes distributing the cooling fluid stream among a plurality of cooling microchannels of the microchannel reactor to comprise a plurality of sub-cooling fluid streams. 
   
     
     
         15 . The process of  claim 1 , further comprising:
 (b2) directing the process stream into a microchannel separation unit operation; and   (b3) performing a heat exchange operation between the process stream and a cooling fluid stream flowing through the microchannel separation unit operation, where the process stream is not in fluid communication with the cooling fluid stream;   wherein:
 step (b2) includes distributing the process stream among a plurality of microchannels to comprise a plurality of sub-process streams, and 
 step (b2) includes distributing the cooling fluid stream into thermal communication with the process stream; and 
 step (b2) includes the step of maintaining separability of the sub-process streams upon entry into the microchannel separation unit operation. 
   
     
     
         16 . The process of  claim 15 , wherein step (b2) includes distributing the cooling fluid stream among a plurality of cooling microchannels of the microchannel separation unit operation that are in thermal communication with the process stream. 
     
     
         17 . The process of  claim 1 , wherein the feed to the microchannel reactor does not include a recycle stream. 
     
     
         18 . The process of  claim 1 , wherein the microchannel reactor includes discrete stages. 
     
     
         19 . The process of  claim 18 , wherein at least one of the discrete stages does not include a recycle stream. 
     
     
         20 . The process of  claim 18 , wherein:
 a first stage of the discrete stages of the microchannel reactor includes a catalyst; and   step (c) includes introducing the feed stream to the catalyst of the first stage for residence times between about 1000 milliseconds to about 10 milliseconds.   
     
     
         21 . The process of  claim 1 , wherein step (d) is carried out within the microchannel reactor. 
     
     
         22 . The process of  claim 18 , wherein a percentage of methanol molecules removed in step (c) from those formed in a first stage of the discrete stages is between about fifty percent to about ninety-five percent. 
     
     
         23 . The process of  claim 1 , further comprising:
 (f) repeating step (c) and step (d) to achieve greater than ninety percent conversion of the carbon containing molecules to form methanol;   wherein: the microchannel reactor includes discrete stages,
 step (d) is first carried out in a second stage of the microchannel reactor, 
 repeated step (d) is carried out in a third stage of the microchannel reactor, downstream from the second stage of the microchannel reactor, 
 an operating temperature of the second stage is higher than an operating temperature of the third stage. 
   
     
     
         24 . The process of  claim 1 , wherein step (a) through step (d) are carried out within a single microchannel assembly. 
     
     
         25 . The process of  claim 1 , wherein the process produces greater than 30 kilograms of methanol molecules per day. 
     
     
         26 . The process of  claim 1 , wherein the microchannel reactor has a displaced volume of less than 200 meters cubed per thousand metric tons of methanol per day. 
     
     
         27 . The process of  claim 1 , wherein the microchannel reactor has a displaced volume of less than 80 meters cubed per thousand metric tons of methanol per day. 
     
     
         28 . The process of  claim 1 , wherein step (a) and step (b) are carried out within a containment vessel. 
     
     
         29 . The process of  claim 1 , wherein:
 the feed stream includes products from a syngas generation process carried out within at least one of a steam reformer, a partial oxidation reactor, and a gasifier; and   a separator interposes the syngas generation process and the microchannel reactor, the separator being operative to remove water from the stream exiting from the syngas generation process.   
     
     
         30 . The process of  claim 29 , wherein:
 the syngas generation process is a natural gas steam reformer and includes microchannels; and   the natural gas steam reforming process is carried out within the microchannels of the steam reformer.   
     
     
         31 . The process of  claim 29 , wherein:
 the water removed by the separator is utilized to cool the microchannel reactor.   
     
     
         32 . The process of  claim 29 , wherein:
 the separator is a microchannel separator;   at least one output stream from the microchannel separator comprises the feed stream to the microchannel reactor; and   a compressor is downstream from the microchannel separator to compress the feed stream before delivery to the microchannel reactor.   
     
     
         33 . The process of  claim 1 , wherein:
 the feed stream includes products from a natural gas steam reforming process carried out within a steam reformer; and   a heat exchanger interposes the steam reformer and the microchannel reactor to remove energy from the products exiting the microchannel reactor;   
     
     
         34 . The process of  claim 33 , wherein:
 the heat exchanger is a microchannel heat exchanger;   at least one output stream from the microchannel heat exchanger comprises the feed stream; and   a compressor is downstream from the microchannel heat exchanger to compress the feed stream before delivery to the microchannel reactor.   
     
     
         35 . The process of  claim 1 , wherein step (c) includes utilizing at least one of a microchannel distillation unit, a capillary separation unit, and a microchannel membrane separation unit to remove at least some of the formed methanol from the process stream. 
     
     
         36 . The process of  claim 1 , wherein the carbon containing molecules and hydrogen containing molecules of the feed stream comprise syngas from at least one of a natural gas stream reforming process, a liquid-to-gassification process, and a solid-to-gasification process. 
     
     
         37 . A process for carrying out at least two unit operations in series, the process comprising the step of:
 directing a feed stream into an integrated assembly which comprises a first microchannel unit operation upon at least one chemical of the feed stream to generate a distributed output stream that exits the first microchannel unit operation in a first set of discrete microchannels isolating flow through the discrete microchannels; and   directing the distributed output stream of the first microchannel unit operation into a second microchannel unit operation as a distributed input stream, to continue isolating flow between the first set of discrete microchannels, and conducting at least one operation upon at least one chemical of the input stream to generate a product stream that exits the second microchannel unit operation;   wherein the first microchannel unit operation and the second unit operation share a housing.   
     
     
         38 . The process of  claim 37 , wherein the operation conducted upon at least one chemical of the input stream includes at least one of a chemical reactor, a chemical separator, a heat exchanger, a compressor, an expander, a vaporizer, a condenser, a phase separator, and a mixer. 
     
     
         39 . The process of  claim 37 , wherein:
 the first microchannel unit operation includes two parallel unit operations, comprising a first parallel unit operation and a second parallel unit operation;   the feed stream is distributed among the two parallel unit operations;   the distributed output stream includes separate distributed output substreams from each of the two parallel unit operations;   the second microchannel operation comprises a heat exchanger;   a first distributed output substream from the first parallel unit operation is fed to the heat exchanger;   a second distributed output substream from the second parallel unit operation is fed to the heat exchanger;   the first distributed output substream is cooled to a lower temperature within the heat exchanger to liquefy a chemical of the first distributed output substream and form a gaseous phase process stream lean in the chemical; and   the second distributed output substream is in thermal communication with the gaseous phase process stream and is operative to elevate the temperature of the gaseous phase process stream.   
     
     
         40 . The process of  claim 37 , wherein:
 the feed stream flowing through the first microchannel unit operation is split among a plurality of microchannels having a plurality of microchannel outlets from the first microchannel unit operation;   the input stream flowing through the second microchannel unit operation is split among a plurality of microchannels having a plurality of microchannel inlets that receive the input stream; and   an interface between first microchannel unit operation and the second microchannel unit operation connects the plurality of microchannel outlets of the first microchannel unit operation to the plurality of microchannel inlets of the second microchannel unit operation while conserving the separability of the streams flowing through the microchannels at the interface.   
     
     
         41 . The process of  claim 37 , wherein at least one of the first microchannel unit operation and the second microchannel unit operation is fabricated using from a laminate structure. 
     
     
         42 . The process of  claim 37 , wherein:
 the first microchannel unit operation conducts a chemical reaction;   the second microchannel unit operation conducts a phase separation operation; and   the chemical reaction conducted in the first microchannel unit operation is equilibrium limited.   
     
     
         43 . The process of  claim 37 , wherein the chemical reaction is at least one of methanol synthesis, ammonia synthesis, Fischer-Tropsch, acetylation, aldol condensation, alkylation, amination, dehydration, esterification, etherification, hydrolysis, isomerization, oligomerization, and transesterification. 
     
     
         44 - 57 . (canceled) 
     
     
         58 . A process for the formation of methanol, the process comprising:
 inputting a hydrocarbon feed stream to a steam reformation reactor that houses a first catalyst;   bringing steam into communication with the hydrocarbon feed stream;   reacting hydrocarbons of the hydrocarbon feed stream with steam in the presence of a catalyst to form a syngas stream comprising carbon dioxide, carbon monoxide and hydrogen;   inputting the syngas stream to a staged microchannel methanol synthesis reactor that houses a second catalyst; and   reacting the syngas in the presence of the second catalyst within the microchannel synthesis reactor to form methanol molecules flowing in a reactant and product stream, where greater than ninety percent of the carbon containing molecules of the syngas, on a carbon basis, are converted into methanol molecules synthesized within the staged microchannel methanol synthesis reactor;   wherein the staged microchannel reactor includes at least three stages, and methanol molecules are removed from the reactant and product stream between at least two of the three stages.   
     
     
         59 . The process of  claim 58 , wherein:
 at least two of the three stages are interposed by unit operation comprising at least one of a microchannel heat exchanger and a microchannel phase separator; and   the unit operation receives an output stream from an immediately upstream stage, where the output stream microchannels flow directly into the microchannels of the unit operation.   
     
     
         60 . The process of  claim 58 , wherein greater than fifty percent of the carbon containing molecules of the syngas, on a carbon basis, are converted into methanol molecules synthesized at the end of the first stage. 
     
     
         61 . The process of  claim 58 , wherein greater than seventy-five percent of the carbon containing molecules of the syngas, on a carbon basis, are converted into methanol molecules synthesized at the end of the second stage. 
     
     
         62 . The process of  claim 58 , wherein the steam reformation reactor includes a microchannel steam reformation reactor. 
     
     
         63 . An integrated microchannel reactor and separator comprising:
 a first network of microchannels housing a first catalyst to facilitate at least one of a molecular cracking reaction or a molecular synthesis reaction;   a second network of microchannels downstream from the first network of microchannels, the second network of microchannels include micropores operative to separate extract at least one of a liquid and a gas flowing through the second network of microchannels, where an interface between the first network of microchannels and the second network of microchannels involves a pressure drop change of less than fifty percent across the interface;   a third network of microchannels housing a second catalyst to facilitate at least one of a molecular cracking reaction or a molecular synthesis reaction, the first network of microchannels being downstream from the second network of microchannels, where an interface between the second network of microchannels and the third network of microchannels involves a pressure drop change of less than fifty percent across the interface; and   a fourth network of microchannels downstream from the third network of microchannels, the fourth network of microchannels include micropores operative to separate extract at least one of a liquid and a gas flowing through the fourth network of microchannels, where an interface between the third network of microchannels and the fourth network of microchannels involves a pressure drop change of less than fifty percent across the interface.   
     
     
         64 . The integrated microchannel reactor and separator of  claim 63 , wherein an interface between the second network of microchannels and the third network of microchannels involves a pressure drop change of less than fifty percent across the interface. 
     
     
         65 . The integrated microchannel reactor and separator of  claim 63 , wherein an interface between the third network of microchannels and the fourth network of microchannels involves a pressure drop change of less than fifty percent across the interface. 
     
     
         66 . The integrated microchannel reactor and separator of  claim 63 , wherein:
 the first catalyst at least one of lines or packs at least a portion of the first network of microchannels; and   the second catalyst at least one of lines or packs at least a portion of the third network of microchannels.   
     
     
         67 . The integrated microchannel reactor and separator of  claim 63 , wherein:
 the pressure drop change of less than fifty percent across the interface is at least partially a result of avoiding consolidation of the microchannels comprising the first microchannel network approximate the interface between the first and second network of microchannels; and   fewer than seventy-five percent of the microchannels of the first microchannel network are consolidated approximate the interface between the first and second network of microchannels.   
     
     
         68 . The integrated microchannel reactor and separator of  claim 64 , wherein:
 the pressure drop change of less than fifty percent across the interface between the second and third microchannel networks is at least partially a result of avoiding consolidation of the microchannels comprising the second microchannel network approximate the interface between the second and third network of microchannels; and   fewer than seventy-five percent of the microchannels of the second microchannel network are consolidated approximate the interface between the second and third network of micro channels.   
     
     
         69 . The integrated microchannel reactor and separator of  claim 65 , wherein:
 the pressure drop change of less than fifty percent across the interface between the third and fourth microchannel networks is at least partially a result of avoiding consolidation of the microchannels comprising the third microchannel network approximate the interface between the third and fourth network of microchannels; and   fewer than seventy-five percent of the microchannels of the third microchannel network are consolidated approximate the interface between the third and fourth network of microchannels.   
     
     
         70 . An integrated microchannel reactor and heat exchanger comprising:
 a corrugated insert sandwiched between opposing shim sheets and mounted to the shim sheets to form a series of microchannels, where each microchannel includes a pair of substantially straight side walls, and a top wall formed by at least one of the opposing shim sheets; and   a first set of microchannels in thermal communication with the corrugated insert.   
     
     
         71 . The integrated microchannel reactor and heat exchanger of  claim 70 , wherein the corrugated insert is fabricated from at least one of aluminum and copper. 
     
     
         72 . The integrated microchannel reactor and heat exchanger of either  claim 70  or  71 , wherein the corrugated insert is fabricated to include right angles so that the series of microchannels have rectangular cross-sections. 
     
     
         73 . The integrated microchannel reactor and heat exchanger of any of  claims 70 - 72 , wherein the corrugated insert at least partially houses a catalyst. 
     
     
         74 . The integrated microchannel reactor and heat exchanger of  claims 73 , wherein:
 the catalyst includes a plurality of particles sized less than 500 microns; and   the plurality of particles within the consecutive microchannels comprise a series of parallel packed beds.   
     
     
         75 . The integrated microchannel reactor and heat exchanger of  claims 74 , wherein:
 the catalyst includes a plurality of particles sized less than 300 microns.   
     
     
         76 . The integrated microchannel reactor and heat exchanger of  claims 74 , wherein:
 the catalyst includes a plurality of particles sized less than 100 microns.   
     
     
         77 . The integrated microchannel reactor and heat exchanger of any of  claims 70 - 76 , wherein:
 at least a plurality of the consecutive microchannels includes an aspect ratio greater than one and one-half.   
     
     
         78 . The integrated microchannel reactor and heat exchanger of  claim 77 , wherein:
 at least a plurality of the consecutive microchannels includes an aspect ratio greater than three.   
     
     
         79 . The integrated microchannel reactor and heat exchanger of any one of  claims 70 - 78 , wherein:
 the corrugated insert has a height ranging between 0.05 to 1 inch.   
     
     
         80 . The integrated microchannel reactor and heat exchanger of any one of  claims 70 - 79 , wherein:
 the first set of microchannels comprise a heat exchanger adapted to carry a cooling fluid to draw off thermal energy from the series of microchannels.   
     
     
         81 . The integrated microchannel reactor and heat exchanger of any one of  claims 73 - 76 , wherein:
 greater than thirty percent of the available volume of the series of microchannels and the first set of microchannels is occupied by the catalyst.   
     
     
         82 . The integrated microchannel reactor and heat exchanger of any one of  claims 70 - 81 , wherein:
 greater than sixty percent of a cross-sectional perimeter of the series of microchannels is provided by the corrugated insert.   
     
     
         83 . The integrated microchannel reactor and heat exchanger of any one of  claims 70 - 82 , wherein:
 a common manifold is in fluid communication with the series of microchannels.   
     
     
         84 . A method of carrying out a Fischer-Tropsch reaction, comprising:
 (a) inputting a feed stream comprising carbon containing molecules and hydrogen containing molecules to a microchannel reactor, the microchannel reactor including a corrugated insert at least partially defining a series of microchannels having an aspect ratio greater than 1.5 and housing a catalyst therein;   (b) reacting a portion of the carbon containing molecules with the hydrogen containing molecules within the microchannel reactor to form hydrocarbon molecules flowing in a process stream;   (c) removing thermal energy from the microchannel reactor using a first set of cooling microchannels in thermal communication with the microchannel reactor; and   (d) removing at least a portion of the hydrocarbon molecules from the microchannel reactor.   
     
     
         85 . The method  claim 84 , wherein the microchannel reactor houses a catalyst. 
     
     
         86 . The method  claim 84  or  85 , wherein:
 the catalyst includes a plurality of particles sized less than 500 microns; and 
 the plurality of particles within the consecutive microchannels comprise a series of parallel packed beds. 
 
     
     
         87 . The method any one of  claims 84 - 86 , wherein the corrugated insert is fabricated from at least one of aluminum and copper. 
     
     
         88 . The method any one of  claims 84 - 87 , wherein the corrugated insert is fabricated to include a series of right angles so that at least a plurality of the microchannels include rectangular cross-sections. 
     
     
         89 . The method any one of  claims 84 - 88 , wherein a ratio of hydrogen containing molecules to carbon containing molecules input to the microchannel reactor is greater than 1. 
     
     
         90 . The method any one of  claims 84 - 89 , wherein:
 the carbon containing molecules include carbon monoxide; and   greater than thirty percent conversion of the carbon monoxide into the hydrocarbon molecules is achieved.   
     
     
         91 . The method of  claim 90 , wherein:
 greater than sixty percent conversion of the carbon monoxide into the hydrocarbon molecules is achieved.   
     
     
         92 . The method of either  claim 90  or  91 , wherein:
 the act of reacting a portion of the carbon containing molecules with the hydrogen containing molecules within the microchannel reactor to form hydrocarbon molecules flowing in a process stream includes a methane selectivity less than twenty percent. 
 
     
     
         93 . The method  claim 86 , wherein:
 a median temperature differential between two of the series of parallel packed beds is within 20 C.   
     
     
         94 . The method  claim 86 , wherein:
 a temperature differential within one of the series of parallel packed beds is within 10 C.   
     
     
         95 . The method of any one of  claims 84 - 94 , wherein:
 the microchannel reactor includes a pair of opposed plates that sandwich the corrugated insert; and   a median heat flux over the opposing plates is greater than 0.5 W/cm 2 .   
     
     
         96 . A method of carrying out a reaction and concurrent heat exchange within a microchannel unit, comprising:
 (a) inputting a feed stream of reactants to a microchannel reactor, the microchannel reactor including a corrugated insert at least partially defining a series of microchannels having an aspect ratio greater than 1.5 and at least partially housing a particulate catalyst therein;   (b) reacting at least a portion of reactants within the microchannel reactor to form product molecules, where the reaction is at least one of methanol synthesis, Fischer-Tropsch, hydrogenation, hydrocracking, oligermization, polymerization, alkylation, sulfonation, nitration, ammonia synthesis, oxidation, and hydrogen peroxide synthesis by direct combination;   (c) removing thermal energy from the microchannel reactor using a first set of cooling microchannels in thermal communication with the microchannel reactor; and   (d) removing at least a portion of the product molecules from the microchannel reactor.   
     
     
         97 . An integrated microchannel reactor and heat exchanger comprising:
 a corrugated insert sandwiched between opposing shim sheets and mounted to the shim sheets to form a series of microchannels; and   a first set of microchannels in thermal communication with the corrugated insert;   wherein greater than thirty percent of the available volume of the series of microchannels is occupied by a particulate catalyst.   
     
     
         98 . The integrated microchannel reactor and heat exchanger of  claim 97 , wherein the corrugated insert is fabricated from at least one of aluminum and copper. 
     
     
         99 . The integrated microchannel reactor and heat exchanger of either  claim 97  or  98 , wherein the corrugated insert is fabricated to include right angles so that the series of microchannels have rectangular cross-sections. 
     
     
         100 . The integrated microchannel reactor and heat exchanger of  claims 97 - 99 , wherein:
 the catalyst includes a plurality of particles sized less than 500 microns; and   the plurality of particles within the series of microchannels comprise a series of parallel packed beds.   
     
     
         101 . The integrated microchannel reactor and heat exchanger of  claims 100 , wherein:
 the catalyst includes a plurality of particles sized less than 300 microns.   
     
     
         102 . The integrated microchannel reactor and heat exchanger of  claims 100 , wherein:
 the catalyst includes a plurality of particles sized less than 100 microns.   
     
     
         103 . The integrated microchannel reactor and heat exchanger of any of  claims 97 - 102 , wherein:
 at least a plurality of the series of microchannels includes an aspect ratio greater than one and one-half   
     
     
         104 . The integrated microchannel reactor and heat exchanger of  claim 103 , wherein:
 at least a plurality of the consecutive microchannels includes an aspect ratio greater than three.   
     
     
         105 . The integrated microchannel reactor and heat exchanger of any one of  claims 97 - 104 , wherein:
 the corrugated insert has a height ranging between 0.05 to 1 inch.   
     
     
         106 . The integrated microchannel reactor and heat exchanger of any one of  claims 97 - 105 , wherein:
 the first set of microchannels comprise a heat exchanger adapted to carry a cooling fluid to draw off thermal energy from the series of microchannels.   
     
     
         107 . The integrated microchannel reactor and heat exchanger of any one of  claims 97 - 106 , wherein:
 greater than sixty percent of a cross-sectional perimeter of the series of microchannels is provided by the corrugated insert.   
     
     
         108 . The integrated microchannel reactor and heat exchanger of any one of  claims 97 - 107 , wherein:
 a common manifold is in fluid communication with the series of microchannels.   
     
     
         109 . An integrated microchannel reactor and heat exchanger comprising:
 a corrugated insert sandwiched between opposing shim sheets and mounted to the shim sheets to form a series of microchannels; and   a first set of microchannels in thermal communication with the corrugated insert;   wherein an aspect ratio for the series of microchannels is greater than one and one-half.   
     
     
         110 . The integrated microchannel reactor and heat exchanger of  claim 109 , wherein the corrugated insert is fabricated from at least one of aluminum and copper. 
     
     
         111 . The integrated microchannel reactor and heat exchanger of either  claim 109  or  110 , wherein the corrugated insert is fabricated to include right angles so that the series of microchannels have rectangular cross-sections. 
     
     
         112 . The integrated microchannel reactor and heat exchanger of any of  claims 109 - 111 , wherein the corrugated insert at least partially houses a catalyst. 
     
     
         113 . The integrated microchannel reactor and heat exchanger of  claims 109 - 112 , wherein:
 the catalyst includes a plurality of particles sized less than 500 microns; and   the plurality of particles within the series of microchannels comprise a series of parallel packed beds.   
     
     
         114 . The integrated microchannel reactor and heat exchanger of  claims 113 , wherein:
 the catalyst includes a plurality of particles sized less than 300 microns.   
     
     
         115 . The integrated microchannel reactor and heat exchanger of  claims 113 , wherein:
 the catalyst includes a plurality of particles sized less than 100 microns.   
     
     
         116 . The integrated microchannel reactor and heat exchanger of  claim 109 - 115 , wherein:
 at least a plurality of the consecutive microchannels includes an aspect ratio greater than three.   
     
     
         117 . The integrated microchannel reactor and heat exchanger of any one of  claims 109 - 116 , wherein:
 the corrugated insert has a height ranging between 0.05 to 1 inch.   
     
     
         118 . The integrated microchannel reactor and heat exchanger of any one of  claims 109 - 117 , wherein:
 the first set of microchannels comprise a heat exchanger adapted to carry a cooling fluid to draw off thermal energy from the series of microchannels.   
     
     
         119 . The integrated microchannel reactor and heat exchanger of any one of  claims 109 - 118 , wherein:
 greater than sixty percent of a cross-sectional perimeter of the series of microchannels is provided by the corrugated insert.   
     
     
         120 . The integrated microchannel reactor and heat exchanger of any one of  claims 109 - 119 , wherein:
 a common manifold is in fluid communication with the series of microchannels.   
     
     
         121 . An integrated microchannel reactor and heat exchanger comprising:
 a corrugated insert sandwiched between opposing shim sheets and mounted to the shim sheets to form a series of microchannels; and   a first set of microchannels in thermal communication with the corrugated insert;   wherein greater than sixty percent of a cross-sectional perimeter of the series of microchannels is provided by the corrugated insert.   
     
     
         122 . The integrated microchannel reactor and heat exchanger of  claim 121 , wherein the corrugated insert is fabricated from at least one of aluminum and copper. 
     
     
         123 . The integrated microchannel reactor and heat exchanger of either  claim 121  or  122 , wherein the corrugated insert is fabricated to include right angles so that the series of microchannels have rectangular cross-sections. 
     
     
         124 . The integrated microchannel reactor and heat exchanger of any of  claims 121 - 123 , wherein the corrugated insert at least partially houses a catalyst. 
     
     
         125 . The integrated microchannel reactor and heat exchanger of  claims 121 - 124 , wherein:
 the catalyst includes a plurality of particles sized less than 500 microns; and   the plurality of particles within the series of microchannels comprise a series of parallel packed beds.   
     
     
         126 . The integrated microchannel reactor and heat exchanger of  claims 125 , wherein:
 the catalyst includes a plurality of particles sized less than 300 microns.   
     
     
         127 . The integrated microchannel reactor and heat exchanger of  claims 125 , wherein:
 the catalyst includes a plurality of particles sized less than 100 microns.   
     
     
         128 . The integrated microchannel reactor and heat exchanger of any of  claims 121 - 127 , wherein:
 at least a plurality of the series of microchannels includes an aspect ratio greater than one and one-half.   
     
     
         129 . The integrated microchannel reactor and heat exchanger of  claim 121 - 128 , wherein:
 at least a plurality of the consecutive microchannels includes an aspect ratio greater than three.   
     
     
         130 . The integrated microchannel reactor and heat exchanger of any one of  claims 121 - 129 , wherein:
 the corrugated insert has a height ranging between 0.05 to 1 inch.   
     
     
         131 . The integrated microchannel reactor and heat exchanger of any one of  claims 121 - 130 , wherein:
 the first set of microchannels comprise a heat exchanger adapted to carry a cooling fluid to draw off thermal energy from the series of microchannels.   
     
     
         132 . The integrated microchannel reactor and heat exchanger of any one of  claims 121 - 131 , wherein:
 a common manifold is in fluid communication with the series of microchannels.   
     
     
         132 . An integrated microchannel reactor and heat exchanger comprising:
 a corrugated insert sandwiched between opposing shim sheets and mounted to the shim sheets to form a series of microchannels; and   a first set of microchannels in thermal communication with the corrugated insert;   wherein the series of microchannels includes more than one hundred microchannels.   
     
     
         133 . The integrated microchannel reactor and heat exchanger of  claim 132 , wherein the corrugated insert is fabricated from at least one of aluminum and copper. 
     
     
         134 . The integrated microchannel reactor and heat exchanger of either  claim 132  or  133 , wherein the corrugated insert is fabricated to include right angles so that the series of microchannels have rectangular cross-sections. 
     
     
         135 . The integrated microchannel reactor and heat exchanger of any of  claims 132 - 134 , wherein the corrugated insert at least partially houses a catalyst. 
     
     
         136 . The integrated microchannel reactor and heat exchanger of  claims 132 - 135 , wherein:
 the catalyst includes a plurality of particles sized less than 500 microns; and   the plurality of particles within the series of microchannels comprise a series of parallel packed beds.   
     
     
         137 . The integrated microchannel reactor and heat exchanger of  claims 136 , wherein:
 the catalyst includes a plurality of particles sized less than 300 microns.   
     
     
         138 . The integrated microchannel reactor and heat exchanger of  claims 136 , wherein:
 the catalyst includes a plurality of particles sized less than 100 microns.   
     
     
         139 . The integrated microchannel reactor and heat exchanger of any of  claims 132 - 138 , wherein:
 at least a plurality of the series of microchannels includes an aspect ratio greater than one and one-half   
     
     
         140 . The integrated microchannel reactor and heat exchanger of  claim 132 - 139 , wherein:
 at least a plurality of the consecutive microchannels includes an aspect ratio greater than three.   
     
     
         141 . The integrated microchannel reactor and heat exchanger of any one of  claims 132 - 140 , wherein:
 the corrugated insert has a height ranging between 0.05 to 1 inch.   
     
     
         142 . The integrated microchannel reactor and heat exchanger of any one of  claims 132 - 141 , wherein:
 the first set of microchannels comprise a heat exchanger adapted to carry a cooling fluid to draw off thermal energy from the series of microchannels.   
     
     
         143 . The integrated microchannel reactor and heat exchanger of any one of  claims 132 - 142 , wherein:
 greater than sixty percent of a cross-sectional perimeter of the series of microchannels is provided by the corrugated insert.   
     
     
         144 . The integrated microchannel reactor and heat exchanger of any one of  claims 132 - 143 , wherein:
 a common manifold is in fluid communication with the series of microchannels.   
     
     
         145 . A method of carrying out a reaction and concurrent heat exchange within a microchannel unit, comprising:
 (a) inputting a feed stream of reactants to a microchannel reactor, the microchannel reactor including a corrugated insert at least partially defining a series of microchannels at least partially housing a particulate catalyst therein, where greater than thirty percent of the available volume of the series of microchannels is occupied by the particulate catalyst;   (b) reacting at least a portion of reactants within the microchannel reactor to form product molecules, where the reaction is at least one of methanol synthesis, Fischer-Tropsch, hydrogenation, hydrocracking, oligermization, polymerization, alkylation, sulfonation, nitration, ammonia synthesis, oxidation, and hydrogen peroxide synthesis by direct combination;   (c) removing thermal energy from the microchannel reactor using a first set of cooling microchannels in thermal communication with the microchannel reactor; and   (d) removing at least a portion of the product molecules from the microchannel reactor.   
     
     
         146 . A method of carrying out a reaction and concurrent heat exchange within a microchannel unit, comprising:
 (a) inputting a feed stream of reactants to a microchannel reactor, the microchannel reactor including a corrugated insert at least partially defining a series of microchannels, wherein greater than sixty percent of a cross-sectional perimeter of the series of microchannels is provided by the corrugated insert;   (b) reacting at least a portion of reactants within the microchannel reactor to form product molecules, where the reaction is at least one of methanol synthesis, Fischer-Tropsch, hydrogenation, hydrocracking, oligermization, polymerization, alkylation, sulfonation, nitration, ammonia synthesis, oxidation, and hydrogen peroxide synthesis by direct combination;   (c) removing thermal energy from the microchannel reactor using a first set of cooling microchannels in thermal communication with the microchannel reactor; and   (d) removing at least a portion of the product molecules from the microchannel reactor.   
     
     
         147 . A method of carrying out a reaction and concurrent heat exchange within a microchannel unit, comprising:
 (a) inputting a feed stream of reactants to a microchannel reactor, the microchannel reactor including a corrugated insert at least partially defining a series of at least one hundred microchannels at least partially housing a particulate catalyst therein;   (b) reacting at least a portion of reactants within the microchannel reactor to form product molecules, where the reaction is at least one of methanol synthesis, Fischer-Tropsch, hydrogenation, hydrocracking, oligermization, polymerization, alkylation, sulfonation, nitration, ammonia synthesis, oxidation, and hydrogen peroxide synthesis by direct combination;   (c) removing thermal energy from the microchannel reactor using a first set of cooling microchannels in thermal communication with the microchannel reactor; and   (d) removing at least a portion of the product molecules from the microchannel reactor.