US Patent 11684903 Microscale chemical reactors

A catalytic microscale reactor with spiral reactor geometry may have a high surface area to volume ratio, high catalytic surface area, high heat transfer surface area, long residence time, and high single pass conversion. The catalytic surface may be treated with microsphere spacer particles which serve to maintain the space between them at an engineered distance without the need for precise manufacturing techniques. The design of the reactor may allow for a catalyst surface to be removed, uncoiled, refurbished, and recoiled in an automated continuous process. An automated continuous process may be suitable both for initially preparing a new catalytic surface as well as refurbishing a fouled catalytic surface and may reduce the time and cost to prepare a new surface.