Continuous flow reaction device for an electrochemical process

Abstract

A continuous flow reaction device ( 100 ) for an electrochemical process comprising: a reaction space ( 110 ), a pumping system ( 200 ) configured to generate a pulsatile flow, a plurality of discrete protrusions ( 120 ,a: 120 ,b ) each configured such that a flow path ( 150 a - 150 c ) of the fluid contacting an inlet end ( 14 ) side of the discrete protrusion is split at least into two daughter flow paths ( 150 b 1; 150 b 2 ) on the outlet end ( 16 ) side of the discrete protrusion ( 120 ,a: 120 ,b ); and the discrete protrusions ( 120 ,a: 120 ,b ) being arranged so that at least one of the daughter flow paths ( 150 b 1 ) generated by one of the plurality of discrete protrusions ( 120 ) combines ( 152 a ) with at least one of the daughter flow paths ( 150 a 2 ) generated by another of the plurality of discrete protrusions ( 120 ) on the outlet end ( 16 ) side of both discrete protrusions ( 120 ) and wherein each (and every) discrete protrusion ( 120 ) is an electrode in the electrochemical process.

What is claimed is: 
     
         1 . A continuous flow reaction device ( 100 ) for an electrochemical process comprising:
 (i.) a reaction space ( 110 ) having a longitudinal (L) direction and transverse (T) direction, (at one longitudinal end) a fluid inlet end ( 14 ) and (at an opposing longitudinal end) a fluid outlet end ( 16 ), and a forward direction (F) from the inlet end ( 14 ) to the outlet end ( 16 );   (ii.) a pumping system ( 200 ) configured to generate a flow to the fluid inlet end ( 14 ), the flow being a pulsatile flow comprising a steady state flow rate and oscillatory flow rate superimposed on the steady state flow rate; and   (iii.) a plurality of discrete protrusions ( 120 , a :  120 , b ) in contact with the reaction space ( 110 ); wherein:
 (a.) each discrete protrusion ( 120 , a :  120 , b ) is configured to comprise a flow path ( 150   a - 150   c ) of the fluid contacting an inlet end ( 14 ) side of the discrete protrusion is split at least into two daughter flow paths ( 150   b   1 ;  150   b   2 ) on the outlet end ( 16 ) side of the discrete protrusion ( 120 , a :  120 , b ); 
 (b.) the discrete protrusions ( 120 , a :  120 , b ) are arranged so that at least one of the daughter flow paths ( 150   b   1 ) generated by one of the plurality of discrete protrusions ( 120 ) combines ( 152   a ) with at least one of the daughter flow paths ( 150   a   2 ) generated by another of the plurality of discrete protrusions ( 120 ) on the outlet end ( 16 ) side of both discrete protrusions ( 120 ); and 
 (c.) each discrete protrusion ( 120 ) is an electrode in the electrochemical process. 
   
     
     
         2 . The device according to  claim 1 , wherein plurality of discrete protrusions ( 120 , a :  120 , b ) in the reaction space ( 110 ) is arranged into a plurality of spatially separated columns (C 1 -C 15 ), wherein the discrete protrusions ( 120 , a :  120 , b ) of the same column are spatially separated on a common linear line, and the distance between adjacent discrete protrusions ( 120 , a :  120 , b ) of the same column is the same. 
     
     
         3 . The device according to  claim 2 , wherein the columns (C 1 -C 15 ) are arranged to comprise daughter flow paths ( 150   b   1 ) combine ( 152   a ) in the spaces between adjacent columns (C 1 -C 15 ). 
     
     
         4 . The device ( 100 ) according to  claim 1 , wherein the discrete protrusions ( 120 , a ;  120 , b ) of opposing polarity are intercalated in the reaction space ( 110 ). 
     
     
         5 . The device ( 100 ) according to  claim 4 , wherein each discrete protrusion ( 120 , a :  120 , b ) of the plurality is an electrode, a node electrode, of one polarity having at least two closest adjacent discrete protrusions that are electrodes, satellite electrodes, of the same polarity, wherein the node electrode has an opposing polarity to the satellite electrodes. 
     
     
         6 . The device ( 100 ) according to  claim 4 , wherein the plurality of discrete protrusions ( 120 , a ;  120 , b ) is disposed on both a longitudinal upper portion ( 142 ) of the reaction space ( 110 ) and on a longitudinal lower portion ( 146 ) of the reaction space ( 110 ), and the discrete protrusions ( 120 , a ;  120 , b ) intercalate when the upper portion ( 142 ) and the lower portion ( 146 ) are brought together. 
     
     
         7 . The device ( 100 ) according to  claim 4 , wherein some of discrete protrusions ( 120 , a ) of the plurality are provided on a first support ( 149   a ) containing a plurality of through-apertures ( 147 ) located between the discrete protrusions ( 120 , a ), and some of discrete protrusions ( 120 , b ) of the plurality are provided on a second support ( 149   b ), wherein the discrete protrusions ( 120 , b ) of the second support ( 149   b ) are arranged to pass through the through-apertures of the first support ( 149   a ), thereby providing the discrete protrusions ( 120 , a ;  120 , b ) of opposing polarity intercalated in the reaction space ( 110 ). 
     
     
         8 . The device ( 100 ) according to  claim 7 , wherein the first support ( 149   a ) and second support ( 149   b ) form a lower portion ( 146 ) of the reaction space ( 110 ) and an upper portion ( 142 ) of the reaction space ( 110 ) is at least partially light-transparent. 
     
     
         9 . The device ( 100 ) according to  claim 1 , wherein each discrete protrusion ( 120 , a ;  120 , b ) comprises:
 (i.) a base end ( 126 , a ) attached to a longitudinal upper base wall ( 144 ) or to a longitudinal lower base wall ( 148 ) of the reaction space ( 110 );   (i.) a free end ( 122 , a,b ) opposing the base end ( 126 , a ); and   (iii.) the discrete protrusions ( 120 , a ;  120 , b ) of the plurality are arranged into two groups of opposing polarity, and disposed in the reaction space to comprise free ends ( 122 , a ) of one group are aligned with the free ends ( 122 , b ) of the other group.   
     
     
         10 . The device ( 100 ) according to  claim 1 , wherein each discrete protrusion ( 120 , a ;  120 , b ) comprises:
 (i.) a base end ( 126 , a ) attached to a longitudinal upper base wall ( 144 ) or to a longitudinal lower base wall ( 148 ) of the reaction space ( 110 );   (ii.) a free end ( 122 , a,b ) opposing the base end ( 126 , a ); and   (iii.) all the discrete protrusions ( 120 , a ;  120 , b ) of the plurality have the same polarity, and are attached to only one of the longitudinal upper base wall ( 144 ) or the longitudinal lower base wall ( 148 ).   
     
     
         11 . The device ( 100 ) according to  claim 1 , wherein the reaction space ( 110 ) is provided in a reaction block ( 102 ), the reaction block ( 102 ) comprising a supporting block ( 170 ) comprising a longitudinal well ( 172 ) for containment and stacking of a plurality of removeable longitudinal inserts ( 174 ,  176 ,  178 ,  182 ), wherein a pair of a longitudinal inserts from the plurality are electrode inserts ( 176 ,  178 ), wherein one or both electrode inserts ( 176 ,  178 ) is disposed with the plurality of discrete protrusions ( 120 , a :  120 , b ). 
     
     
         12 . The device according to  claim 11 , wherein one of the longitudinal inserts from the plurality is a spacing/sealing insert ( 178 ) providing longitudinal side walls ( 131 ,  132 ) and first ( 134 ) and second ( 136 ) end walls ( 134 ) of the reaction space. 
     
     
         13 . The device ( 100 ) according to  claim 11 , wherein the reaction block ( 102 ) further comprises a heat exchanger ( 186 ). 
     
     
         14 . The device ( 100 ) according to  claim 1 , further comprising a voltage generator ( 300 ) for generation of a voltage potential applied across electrodes of opposing polarity, wherein the voltage generator is configured for:
 (i.) generation of a voltage, a fixed voltage, at a fixed and continuous level, and/or   (ii.) generation of a voltage, a variable voltage, generated at two or more different levels over time,
 optionally, wherein the variable voltage regularly varies between two or more values, optionally wherein the variable voltage regularly varies between high and low value, and/or between a positive and negative value, and/or between a positive/negative value and to zero. 
   
     
     
         15 . The device ( 100 ) according to  claim 1 , wherein:
 (i.) one or both electrode surfaces of opposing polarity is formed at least partially from an electrocatalyst, and/or is at least partially coated with an electrocatalyst, and/or   (ii.) one or both electrode surfaces of opposing polarity is formed at least partially from a photocatalyst, and/or is at least partially coated with a photocatalyst, and/or   (iii.) one or both electrode surfaces of opposing polarity is partially coated with an electrically insulative layer.