CA2747874A1 - Process for forming an emulsion using microchannel process technology - Google Patents

Process for forming an emulsion using microchannel process technology Download PDF

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Publication number
CA2747874A1
CA2747874A1 CA2747874A CA2747874A CA2747874A1 CA 2747874 A1 CA2747874 A1 CA 2747874A1 CA 2747874 A CA2747874 A CA 2747874A CA 2747874 A CA2747874 A CA 2747874A CA 2747874 A1 CA2747874 A1 CA 2747874A1
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Canada
Prior art keywords
microchannel
emulsion
liquid
conducted
microchannels
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Granted
Application number
CA2747874A
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French (fr)
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CA2747874C (en
Inventor
Dongming Qiu
Anna Lee Tonkovich
Laura J. Silva
Richard Q. Long
Barry L. Yang
Kristina Marie Trenkamp
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Velocys Inc
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Velocys Inc
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Priority claimed from CA2526965A external-priority patent/CA2526965C/en
Publication of CA2747874A1 publication Critical patent/CA2747874A1/en
Application granted granted Critical
Publication of CA2747874C publication Critical patent/CA2747874C/en
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K8/00—Cosmetics or similar toiletry preparations
    • A61K8/02—Cosmetics or similar toiletry preparations characterised by special physical form
    • A61K8/04—Dispersions; Emulsions
    • A61K8/06—Emulsions
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61Q—SPECIFIC USE OF COSMETICS OR SIMILAR TOILETRY PREPARATIONS
    • A61Q19/00—Preparations for care of the skin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
    • B01F23/40—Mixing liquids with liquids; Emulsifying
    • B01F23/41—Emulsifying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
    • B01F23/40—Mixing liquids with liquids; Emulsifying
    • B01F23/41—Emulsifying
    • B01F23/414—Emulsifying characterised by the internal structure of the emulsion
    • B01F23/4145—Emulsions of oils, e.g. fuel, and water
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
    • B01F25/30—Injector mixers
    • B01F25/31—Injector mixers in conduits or tubes through which the main component flows
    • B01F25/314—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced at the circumference of the conduit
    • B01F25/3142—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced at the circumference of the conduit the conduit having a plurality of openings in the axial direction or in the circumferential direction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
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    • B01F25/30—Injector mixers
    • B01F25/31—Injector mixers in conduits or tubes through which the main component flows
    • B01F25/314—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced at the circumference of the conduit
    • B01F25/3142—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced at the circumference of the conduit the conduit having a plurality of openings in the axial direction or in the circumferential direction
    • B01F25/31421—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced at the circumference of the conduit the conduit having a plurality of openings in the axial direction or in the circumferential direction the conduit being porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01F25/31—Injector mixers in conduits or tubes through which the main component flows
    • B01F25/314—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced at the circumference of the conduit
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    • B01F25/31424—Injector mixers in conduits or tubes through which the main component flows wherein additional components are introduced at the circumference of the conduit the conduit having a plurality of openings in the axial direction or in the circumferential direction with a plurality of perforations aligned in a row perpendicular to the flow direction
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01F35/00—Accessories for mixers; Auxiliary operations or auxiliary devices; Parts or details of general application
    • B01F35/90—Heating or cooling systems
    • B01F35/92—Heating or cooling systems for heating the outside of the receptacle, e.g. heated jackets or burners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00781—Aspects relating to microreactors
    • B01J2219/00873—Heat exchange
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J2219/00889—Mixing
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
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    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
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    • C10L1/19—Esters ester radical containing compounds; ester ethers; carbonic acid esters
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
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    • C10L1/18—Organic compounds containing oxygen
    • C10L1/19—Esters ester radical containing compounds; ester ethers; carbonic acid esters
    • C10L1/191—Esters ester radical containing compounds; ester ethers; carbonic acid esters of di- or polyhydroxyalcohols
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
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    • C10L1/198—Macromolecular compounds obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds homo- or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon to carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, of carbonic acid
    • C10L1/1985—Macromolecular compounds obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds homo- or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon to carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, of carbonic acid polyethers, e.g. di- polygylcols and derivatives; ethers - esters
    • C—CHEMISTRY; METALLURGY
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    • C—CHEMISTRY; METALLURGY
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    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
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    • C10L1/232—Organic compounds containing nitrogen containing nitrogen in a heterocyclic ring
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    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
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    • C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
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    • F28F2260/02—Heat exchangers or heat exchange elements having special size, e.g. microstructures having microchannels
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10S516/924—Significant dispersive or manipulative operation or step in making or stabilizing colloid system

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  • Dispersion Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Dermatology (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Colloid Chemistry (AREA)

Abstract

The disclosed invention relates to a process for making an emulsion. The process comprises: flowing a first liquid through a process microchannel, the process microchannel having a wall with an apertured section; flowing a second liquid through the apertured section into the process microchannel in contact with the first liquid, the first liquid forming a continuous phase, the second liquid forming a discontinuous phase dispersed in the continuous phase.

Claims (43)

1. A process, comprising:
flowing an emulsion in a process microchannel; and exchanging heat between the process microchannel and a heat exchanger, the heat flux between the process microchannel and the heat exchanger being in the range from 0.01 to 250 watts per square centimeter of surface area of the process microchannel.
2. The process of claim 1 wherein the heat exchanger comprises a heat exchange channel, an electric heating element, a resistance heater, and/or a non-fluid cooling element.
3. The process of claim 1 or claim 2 wherein the process microchannel comprises at least one wall, the temperature gradient between the process microchannel wall and the bulk flow of the emulsion within the process microchannel being less than 5°C.
4. The process of any one of claims 1 to 3 wherein the heat exchanger comprises a plurality of temperature zones along the length of the process microchannel.
5. The process of any one of claims 1 to 4 wherein the velocity of the emulsion flowing in the process microchannel is in the range from 0.01 to 100 meters per second.
6. The process of any one of claims 1 to 5 wherein the heat exchanger comprises a heat exchange channel, a heat exchange fluid being in the heat exchange channel, the heat exchange fluid undergoing a phase change in the heat exchange channel.
7. The process of any one of claims 1 to 6 wherein the heat exchanger comprises a heat exchange channel, an endothermic process being conducted in the heat exchange channel or an exothermic process being conducted in the heat exchange channel.
8. The process of any one of claims 1 to 7 wherein the emulsion is quenched in the process microchannel.
9. The process of claim 2 wherein the heat exchange channel comprises a microchannel.
10. The process of any one of claims 1 to 9 wherein the emulsion comprises a first liquid and a second liquid which are mixed with each other in the process microchannel to form the emulsion.
11. The process of any one of claims 1 to 10 wherein the process microchannel has a mixing zone with a restricted cross section.
12. The process of any one of claims 1 to 11 wherein the process microchannel has a sidewall with an apertured section, the emulsion comprising a first liquid and a second liquid, the first liquid flowing in the process microchannel, and the second liquid flowing through the apertured section into the process microchannel and mixing with the first liquid to form the emulsion.
13. The process of claim 12 wherein the second liquid flows from a liquid channel through the apertured section.
14. The process of any one of claims 1 to 13 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising a plurality of the process microchannels, the process microchannels having adjacent liquid channels, the process microchannels and liquid channels being formed from parallel spaced sheets or plates, the process microchannels and liquid channels being adjacent to each other and aligned in interleaved side-by-side vertically oriented planes or interleaved horizontally oriented planes stacked one above another.
15. The process of claim 14 wherein the microchannel mixer further comprises a plurality of heat exchange channels formed from parallel spaced sheets or plates, the heat exchange channels being adjacent to the process microchannels, the liquid channels, or both the process microchannels and the liquid channels.
16. The process of any one of claims 1 to 15 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising a plurality of the process microchannels wherein separate emulsions are formed in each of the process microchannels, the emulsions formed in at least two of the process microchannels being different from each other.
17. The process of any one of claims 1 to 16 wherein the process microchannel has an internal dimension of up to about 50 mm.
18. The process of any one of claims 1 to 17 wherein the process microchannel has an internal dimension of up to about 10 mm.
19. The process of any one of claims 1 to 18 wherein the emulsion comprises a water-in-oil emulsion.
20. The process of any one of claims 1 to 19 wherein the emulsion comprises an oil-in-water emulsion.
21. The process of any one of claims 1 to 20 wherein the emulsion comprises a water-in-oil-in-water emulsion.
22. The process of any one of claims 1 to 21 wherein the emulsion comprises an oil-in-water-in-oil emulsion.
23. The process of any one of claims 1 to 22 wherein the emulsion comprises at least one emulsifier and/or surfactant.
24. The process of any one of claims 1 to 23 wherein the emulsion comprises one or more: UV protection factors; waxes; consistency factors;
thickeners; superfatting agents; stabilizers; cationic, anionic, zwitterionic, amphoteric or nonionic polymers; silicone compounds; fats; waxes; lecithins;
phospholipids;
biogenic agents; antioxidants; deodorants; antiperspirants; antidandruff agents;
swelling agents; insect repellents; self-tanning agents; tyrosine inhibitors;
solubilizers; preservatives; perfume oils; or dyes; or a mixture of two or more thereof.
25. The process of any one of claims 1 to 24 wherein solids are dispersed in the emulsion.
26. The process of any one of claims 1 to 25 wherein pigment is dispersed in the emulsion.
27. The process of any one of claims 1 to 26 wherein a catalyst is dispersed in the emulsion.
28. The process of any one of claims 1 to 27 wherein optical or thermal-optical features of the emulsion are adjusted in the process microchannel.
29. The process of any one of claims 1 to 28 wherein a chemical reaction is conducted in the process microchannel.
30. The process of any one of claims 1 to 29 wherein a biological process is conducted in the process microchannel.
31. The process of any one of claims 1 to 30 wherein a liquid adsorption process is conducted in the process microchannel.
32. The process of any one of claims 1 to 31 wherein a liquid-gas adsorption process is conducted in the process microchannel.
33. The process of any one of claims 1 to 32 wherein a liquid separation process is conducted in the process microchannel.
34. The process of any one of claims 1 to 33 wherein a solidification process is conducted in the process microchannel.
35. The process of any one of claims 1 to 34 wherein a gasification process is conducted in the process microchannel.
36. The process of any one of claims 1 to 35 wherein the emulsion is used to track charged particles.
37. The process of any one of claims 1 to 36 wherein the process produces at least 1 liter of emulsion per minute.
38. The process of any one of claims 1 to 37 wherein the process produces at least 1 liter of emulsion per second.
39. The process of any one of claims 1 to 38 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising at least two of the process microchannels.
40. The process of any one of claims 1 to 39 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising at least about 10 of the process microchannels.
41. The process of any one of claims 1 to 40 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising at least about 100 of the process microchannels.
42. The process of any one of claims 1 to 41 wherein the process is conducted in a microchannel mixer, the microchannel mixer comprising at least about 1000 of the process microchannels.
43. The process of any one of claims 1 to 42 wherein the emulsion comprises a skin care product, paint or coating composition, adhesive composition, glue composition, caulk composition, sealant, food composition, agricultural composition, fuel composition, lubricant composition, surface dressing, silicone emulsion, composition comprising crystals, liquid crystal composition, wax emulsion, or a double emulsion.
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EP2266684A2 (en) 2010-12-29
CA2747874C (en) 2012-11-27
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EP2266685A2 (en) 2010-12-29
EP2266684A3 (en) 2011-03-23
US7485671B2 (en) 2009-02-03
EP2266685B1 (en) 2012-08-22
EP2266685A3 (en) 2011-03-23
US20040228882A1 (en) 2004-11-18

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