patrick löb, christian hofmann, ulrich krtschil, gabriele ......© fraunhofer ict-imm – p. löb,...

© Fraunhofer ICT-IMM – P. Löb, C. Hofmann, U. Krtschil, G. Menges-Flanagan

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Patrick Löb, Christian Hofmann, Ulrich Krtschil, Gabriele Menges-Flanagan Bereich Energie- und ChemietechnikFraunhofer ICT-IMM, Mainz

NUTZUNG ADDITIVER FERTIGUNGSVERFAHRENZUR REALISIERUNG STRUKTURIERTER CHEMISCHER REAKTOREN

Ludwigshafen, 16. März 2017

[email protected]


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Content

Introduction

Background Fraunhofer ICT-IMM Additive manufacturing / Selective Laser Melting (SLM)

for metallic parts

Examples of microstructured reactors of Fraunhofer ICT-IMM realisedby SLM (by multiple external service providers):

Compact cylindrical microstructured devices (three different versions)

Lab-scale microreactor modules for process development

Special reactor in lab- and pilot-/small production scale for the synthesis of Grignard reagents

Cost considerations

Related examples from literature

Summary - Advantages/potentials – disadvantages/limitations


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Fraunhofer ICT-IMM and its services in the field of Chemical Micro Process Engineering

All activities are dedicated to the optimisation or reinvention of chemical production processes by methods and components of chemical micro process technology.

Offered services:

Development, realisation and provision of components and plants

Microreactors for lab scale & for pilot and production scale

Specialised micro structured apparatuses

Individual small scale plants

Process development up to piloting and production (focus on organic chemistry)


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ICT-IMM has a long track in developing and realizing microstructured reactors

micro mixers

micro heat exchangers

micro reactors for heterogeneouslycatalysed reactions

micro reactors forelectroorganic synthesis

micro structuredg/l contacting devices


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Example 1: Compact cylindrical microstructured devices- Tubular Heat Transfer Micro Device First contact! - First microstructure-bearing metallic (stainless steel)

component of Fraunhofer ICT-IMM realised by additive manufacturing

Tubular Heat Transfer Micro Device (THTMD)

„conventional“ device

3D printed device

“Conventional” device realised in several steps using costly manufacturing technology

Simplification of realisation

Positive experience regular consideration of additive manufacturing also for the realisation of structured, metallic components

wire spark erosionlaser welding

Why additive manufacturing?0.3 mm x 1.2 mm x 100 mm

Channels inside: ca. 0.5 mm x 2 mm x 100 mm


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Example 1: Compact cylindrical microstructured devices- Cylindrical microstructured heat exchanger

Further processing: addition of tubes by laser welding


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Example 1: Compact cylindrical microstructured devices- Cylindrical microstructured heat exchangerIllustration of functional principle


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Hole required for fabrication process (powder removal)& for later use for insertion of an thermocouple

Cross section


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ca. 650 μm ca. 340 μm

Typical layer thickness: 30 – 50 μm

Structure precision and surface quality


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Example 2: Lab-scale modular microreactor realised byadditive manufacturing

Explosion view of a singlemicroreactor module

Distributor/cover plate

Core reaction module

heat exchange fluidreaction fluid

Target application: organic-chemical reactions, lab process development


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Example 2: Lab-scale modular microreactor realised byadditive manufacturing

Reactor assembly ofthree single modules

Single reactormodule Why additive manufacturing?

Prototype production, i.e. small numbers required

Complex device Conventional fabri-cation more expensive.

Fast realisation (typically < 10 work. days)


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Example 3: Special reactor in lab- and pilot-/small production scale for the synthesis of Grignard reagents

Ca.

100

mm

Inner diameter:ca. 20 mm

Lab-scale reactorCore cartridge reactor

Distributor plate withintegrated heat exchanger


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Example 3: Special reactor in lab- and pilot-/small production scale for the synthesis of Grignard reagents

pilot-/small productionscale reactor

ca. 73 cm


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Cost considerations Example: microreactor module in two scales

About 0.2 L reaction volume & about 2.3 L reaction volume

Considered cases:

Additive manufacturing

Plate stack: plate structuring by roll embossing, brazing

Plate stack: plate structuring by wet chemical etching, brazing Allgemeine Annahmen: Fertigung von 1 Stück, ohne Deckel und Anschlüsse, ohne Konstruktion, etc.

Pilot-scaleIndustrial-

scale

Walzen, löten 1,5 3,6 Annahme: Walzen und Walzstraße vorhanden

Ätzen, löten 1,0 3,2

Selektives Laserschmelzen (3D-Drucken)

1,3 10,0Annahme f. Industrial-scale: Extrapolation aus vorhandenen Angeboten, kann ggf. erheblich

günstiger werden

Fertigungsverfahren Bemerkungen:Reaktorgröße

Anmerkung: Die Variante "Walzen" bestehen aus viel mehr Einzelteilen, das bedeutet mehr manuellen Montageaufwand


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Summary

Advantages / potentials

Fast realisation of prototypes, small devices, small serial production

In this context then also advantageous in view of costs compared to conventional fabrication approaches

Additive manufacturing allows also complex geometries (e.g. fluid guidance) typically realisable by conventional manufacturing only in several steps

Micro-/milli-structuring: so far reached/used

Closed channels: down to 0.5 mm x 0.5 mm x 100 mm

Open structures, e.g. fins: down to 0.2 mm x 0.6 mm

Remaining wall thicknesses - Separation layers between different fluids: ca. 0.5 mm- Fins between channels: ca. 0.3 mm

Examples from Fraunhofer ICT-IMM working areas shown

Focused on realising prototypes or small series of devices

SLM manufacturing done by external service providers


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Summary

Disadvantages / limitations

Efforts and know-how required to adopt the design according to SLM manufacturing

For higher piece numbers (serial production) typically no dramatic decrease of price per piece (no typical economy of scale). Then again competition with conventional approaches

Smaller structures limited by layer thickness, melting process and surface roughness.

Interaction with external service providers needed, e.g. exchange of CAM files

Limited control over the manufacturing process (e.g. part orientation during fabrication)

Siehe auch zum Vergleich: DECHEMA / Praxisforum – 2015: White Paper: Die 7 Mythen der Additiven Fertigung

Kontakt: Dr. Patrick Löb - [email protected]

patrick löb, christian hofmann, ulrich krtschil, gabriele ......© fraunhofer ict-imm – p. löb,...

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