Apparatus and methods for parallel processing of multiple reaction mixtures

Abstract

A parallel reactor system including a reactor and vessels in the reactor for holding reaction mixtures, and a cannula for introducing fluid reaction material into the vessels. A robot system is operable to insert the cannula into cannula passages in the reactor for delivery of reaction materials, including slurries, to respective vessels, and to withdraw the cannula from the cannula passages after delivery. Related methods are also disclosed.

What is claimed is:  
     
         1 . A method of preparing and delivering a slurry into a series of vessels, said method comprising: 
 (1) mixing a particulate solid material and a liquid dispersing medium and agitating the mixture to form a substantially homogeneous first slurry in which said particulate solid material is suspended in the liquid;    (2) aspirating the slurry into a cannula carried by a robot system while the slurry is substantially homogeneous;    (3) operating the robot system to insert the cannula into a vessel;    (4) delivering the slurry from the cannula into the vessel while the cannula is in said vessel; and    (5) repeating (2)-(4) for a second vessel with said first slurry or repeating (2)-(4) for a second vessel with a second slurry.    
     
     
         2 . A method as set forth in  claim 1  wherein said aspirating occurs during said agitating.  
     
     
         3 . A method as set forth in  claim 1  wherein said slurry is delivered to said vessel while the slurry is still substantially homogenous.  
     
     
         4 . A method as set forth in  claim 3  wherein said slurry is delivered to said vessel within 60 seconds of said aspirating.  
     
     
         5 . A method as set forth in  claim 1  wherein said agitating is accomplished by vortexing.  
     
     
         6 . A method as set forth in  claim 1  further comprising aspirating a barrier liquid into said cannula after aspirating said slurry and before delivering said slurry.  
     
     
         7 . A method as set forth in  claim 1  wherein at least one of said slurries comprises a catalyst.  
     
     
         8 . A method as set forth in  claim 7  wherein said catalyst is supported on said particulate solid material.  
     
     
         9 . A method as set forth in  claim 1  wherein at least one of said slurries is prepared less than 90 minutes before delivery to said vessel.  
     
     
         10 . A method as set forth in  claim 9  wherein at least one of said slurries is prepared not more than 45 minutes before delivery to said vessel.  
     
     
         11 . A method as set forth in  claim 10  wherein at least one of said slurries is prepared not more than 10 minutes before delivery to said vessel.  
     
     
         12 . A method as set forth in  claim 11  wherein at least one of said slurries is prepared not more than 5 minutes before delivery to said vessel.  
     
     
         13 . A method as set forth in  claim 12  wherein at least one of said slurries is prepared not more than 1 minute before delivery to said vessel.  
     
     
         14 . A method as set forth in  claim 13  wherein at least one of said slurries is prepared not more than 30 seconds before delivery to said vessel.  
     
     
         15 . A method as set forth in  claim 1  wherein at least one of said vessels into which one of said slurries is delivered is pressurized.  
     
     
         16 . A method as set forth in  claim 15  wherein said one of said slurries is delivered at a pressure of up to 500 psig or greater.  
     
     
         17 . A method as set forth in  claim 1  wherein said first and second slurries are of different composition.  
     
     
         18 . A method as set forth in  claim 1  further comprising controlling at least two of said mixing, agitating, aspirating, operating, and delivering with a system processor.  
     
     
         19 . A method as set forth in  claim 1  further comprising controlling said mixing, agitating, aspirating, operating, and delivering with said system processor.  
     
     
         20 . A method of processing mixtures in a series of vessels, said method comprising: 
 (1) mixing a particulate solid material and a liquid dispersing medium and agitating the mixture to form a substantially homogeneous first slurry in which said particulate solid material is suspended in the liquid;    (2) aspirating the slurry into a cannula carried by a robot system while the slurry is substantially homogeneous;    (3) operating the robot system to insert the cannula into a vessel;    (4) delivering the slurry from the cannula into the vessel while the cannula is in said vessel;    (5) repeating (2)-(4) for a second vessel with said first slurry or repeating (2)-(4) for a second vessel with a second slurry; and    (6) processing mixtures comprising said slurries in said vessels.    
     
     
         21 . A method as set forth in  claim 20  wherein at least one of said slurries comprises a catalyst for catalyzing a reaction of reaction materials in said mixtures and said processing comprises reacting said reaction materials.  
     
     
         22 . A method as set forth in  claim 21  wherein said reaction comprises a polymerization reaction.  
     
     
         23 . A method as set forth in  claim 22  further comprising evaluating catalyst performance of said catalyst.  
     
     
         24 . A method as set forth in  claim 20  further comprising controlling at least two of said mixing, agitating, aspirating, operating, delivering, and processing with a system processor.  
     
     
         25 . A method as set forth in  claim 24  further comprising controlling said mixing, agitating, aspirating, operating, delivering, and processing with said system processor.