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Microchannel
chemical processing technology is an emerging field with applications
in most industrial processes due to excellent mixing, controlled
reaction environment, and energy efficiency. This technology offers
improvements in existing processes and will enable new processes
to become cost effective. Of particular interest is the reformation
of hydrocarbons to hydrogen for fuel cell applications, the upgrading
of natural gas to high value liquids, and the conversion of carbon
dioxide to useful products which do not contribute to global warming. |
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The
basic MEI microchannel reactor design is based on the flow between
parallel platelets coated with catalyst. The large aspect ratio
of the channel provides extensive surface area in a small volume.
Microchannel reactors were developed based on ceramic substrates
as well as metal substrates. In both types of reactors, multiple
layers coated with catalytic material are bonded, forming a monolithic
structure. An added benefit of a layered pattern is the ability
to easily scale up or down by adjusting the number of layers.
This provides great flexibility in the design if desired production
capacity is changed, without the need to redesign the reactor
(as it would be the case in a tubular reactor). |
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Makel
Engineering has developed techniques to deposit various catalysts
directly into the microchannel layers, including catalysts for
methane reformation, carbon monoxide and dioxide methanation,
water gas shift reaction, and preferred oxidation of carbon monoxide.
The result is a thin layer of catalyst (order of hundreds of microns)
that does not generate significant pressure drop, and is not susceptible
to settling, a problem common to packed beds. |
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MEI’s
ceramic-based reactors use laser machined ceramic platelets to
form the reactor structure. Catalyst is applied to the laser machined
ceramic, providing a robust catalyst that is not susceptible to
settling and does not increase pressure drop of the system. Due
to they inert nature, ceramic substrates are compatible with most
reaction media, even at high temperatures. They also enable incorporation
of printed patterns for heaters and temperature sensors. |
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MEI’s
metal-based reactors use etched metal platelets to form the reactor
structure. Catalyst is applied to the etched platelets by a method
similar to that used for ceramic platelets. Multiple layers are
bonded forming the microchannel reactor. The metal-based reactors
have better mechanical properties, such as being tolerant to vibration
and thermal cycling, compared to ceramic-based reactors. Incorporation
of auxiliary components such as heat exchangers, manifolds, condensers,
which are usually metal-based, is facilitated as well. |
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