The impact of additive manufacturing on micro reactor technology (slideshare 17 juni 2015)

The impact of additive manufacturing on micro reactor technology

R.ReintjensCompetence manager PIDSM ChemTech R&[email protected]

mailto:[email protected]

Micro reactor principles

Mass and heat transfer fundamentals

D = Diffusion coëfficiënt [m2/s]

λ = Heat conductivity coëfficient [W/mK]

A = Transfer surface area [m2]

ΔC = Concentration difference [mol/m3]

ΔT = Temperature difference [K]

Δx = Transfer distance [m]

A (m2)

C1 C2

Transfer time scales

Transfer time depends strongly on transfer distance

The micro reactor is just a tube reactor

B

Amixer

The design equals a conventional tube reactor with small diameter

The channel diameter is a key aspect

C

jacketed tube reactor

HTF-in

HTF-out

Impact of laminar flow

convective diffusion

tube diameter

turbulent intermediate laminar

hydrodynamics

At such small diameters the flow mode goes to laminar

Laminar flow mode gives less control over time

The lab micro reactor became a hype

The industrial micro reactor is lagging

Only a few industrial reactorsVast number of publications

Supplier (labscale) shake out

Hurdles towards industrial application

What is your ‘product’, information or mass?

Information, dataµL reactor volumeSize is irrelevant

Product, mass

1-100 ltr reactor volumeSize is relevant

How many channels are required on industrial scale ?

Channel dimensions: 100 micron ID, 1 m lengthProductivity 10.000 – 100.000 kg/m3h

The numbering up hurdle

Small channel diameter micro reactors will be difficult to manufacture

Impact of manufacturing

Manufacturing technologies

Alfa LavalESK

Micronit

Construction materials

Channel

MachiningLaser ablatingDeep ion etchingEtchingSandblastingPunchingSpark erosionExtrusionEmbossing

Parallelization

StackingClampingDiffusion bondingLaser weldingBrazing

Manufacturing technology has a strong impact

How to move forward?

2012

2010

2008

We developed metrics for economic evaluation

We evaluated manufacturing technologies

We set up a database of capable MR suppliers

2014

Solving the contradiction

100 μm 1-4

mm

• bad performance• Easy to manufacture, lower

cost

• high performance• too difficult, too

expensive

Design for secondary flow

Primary flow

Dean vortices (secondary flow)

Increasing• curvature• velocity

A-A A-A A-A

instabile / chaotic

in time

and position

stabile

µm thick fluid layers are created

Applying zigzag channel layout

Water

ID 1.22 mm

Re = 14

At low Re number the flow is pure laminarNo secondary flow effect occurs

Impact of fluid velocity

Re = 137 Re = 273 Re = 546

At higher Re number secondary flow occursAnd gets more chaotic

CFD as part of the development loop

CFDmodel

construction

Performance

test

Dosing reactants with a T-mixer

Experiment CFD

150 mm

500 mm

1500 mm

Experiment CFD

N.Kockmann, IMTEK Freiburg

Design strategy for industrial micro reactors

PLd N

• Maximize channel volume (diameter, length)

• Maximize channel performance (shape, geometry)

• Keep geometry equal

• Number up to N channels per module (manifold)

• Use P modules in parallel to obtain volume

Manufacturability

Performance

Additive manufacturing

An innovative manufacturing technology

Characteristics• Energy efficiency • Low material waste • Rapid product

development• Freedom of design• Customizable

Application areas• Industrial design

• Automotive • Aerospace, aviation• Dental, implants• Functional parts

#/year

Sales AMT machines (worldwide)

Overview of AM technologies

BJ Binder JettingEBM Electron Beam MeltingFDM Fused Deposition ModelingLM Laser MeltingLS Laser SinteringMJ Material JettingPJ Photopolymer JettingSL Stereo Lithography

https://www.additively.com

Selective Laser Melting (metal)

Developed by ILT Fraunhofer Aachen (1995)

Max build envelop 60x40x50 cm3Min feature size 40-200 micronMin layer thickness 30 micronAccuracy 20-50 micronSurface finish 4-10 micron RADensity 99.9%

AluminiumCobalt-chromium alloyNickel based alloysStainless steelTitaniumTantalumTungsten

selective laser melting process produces homogenous metal objects directly from 3D CAD data by selectively melting fine layers of metal powder with a laser beam.

SLM freedom of design

SLM economic evaluation

Concept Laser

Renishaw

http://www.emdt.co.uk/print/3529

316L stainless steel

SLM Solutions GmbH

Sales SLM machines per year

SLM for micro reactor manufacturing

Efficient in construction material consumption

Intricate details possible in mm sized channels

SLM provides significant benefits

SS, Ta

design freedom

combinedcompetitive cost level

Construction materials

Manufacturing technologies

SLM will be a strong enabler

Industrial micro reactors

DSM design expertise

Selective laser melting

Freedom of designFavorable economics

The impact of additive manufacturing on micro reactor technology (slideshare 17 juni 2015)

Technology

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