Title: High aspect ratio catalytic reactor and catalyst inserts therefor

Abstract

The present invention relates to high efficient tubular catalytic steam reforming reactor configured from about 0.2 inch to about 2 inch inside diameter high temperature metal alloy tube or pipe and loaded with a plurality of rolled catalyst inserts comprising metallic monoliths. The catalyst insert substrate is formed from a single metal foil without a central supporting structure in the form of a spiral monolith. The single metal foil is treated to have 3-dimensional surface features that provide mechanical support and establish open gas channels between each of the rolled layers. This unique geometry accelerates gas mixing and heat transfer and provides a high catalytic active surface area. The small diameter, high aspect ratio tubular catalytic steam reforming reactors loaded with rolled catalyst inserts can be arranged in a multi-pass non-vertical parallel configuration thermally coupled with a heat source to carry out steam reforming of hydrocarbon-containing feeds. The rolled catalyst inserts are self-supported on the reactor wall and enable efficient heat transfer from the reactor wall to the reactor interior, and lower pressure drop than known particulate catalysts. The heat source can be oxygen transport membrane reactors.

Inventors:

Lin, Jiefeng; Kelly, Sean M.

Issue Date:

2018-04-10

Research Org.:

Praxair, Inc., Danbury, CT (United States)

Sponsoring Org.:

USDOE

OSTI Identifier:

1434707

Patent Number(s):

9938146

Application Number:

14/979,790

Assignee:

PRAXAIR TECHNOLOGY, INC. (Danbury, CT)

Patent Classifications (CPCs):

C - CHEMISTRY C01 - INORGANIC CHEMISTRY C01B - NON-METALLIC ELEMENTS

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

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C - CHEMISTRY C01 - INORGANIC CHEMISTRY C01B - NON-METALLIC ELEMENTS

C01B2203/1241 - Natural gas or methane

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J19/2485 - {Monolithic reactors}
B01J15/005 - {in the presence of catalytically active bodies, e.g. porous plates}
B01J2219/32425 - Ceramic
B01J19/243 - {spirally, concentrically or zigzag wound}
B01J19/2415 - {Tubular reactors}

C - CHEMISTRY C01 - INORGANIC CHEMISTRY C01B - NON-METALLIC ELEMENTS

C01B2203/1023 - Catalysts in the form of a monolith or honeycomb

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02P - CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

Y02P20/10 - General improvement of production processes causing greenhouse gases [GHG] emissions

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J2219/30292 - rolled up
B01J2219/32408 - Metal
B01J19/32 - Packing elements in the form of grids or built-up elements for forming a unit or module inside the apparatus for mass or heat transfer

C - CHEMISTRY C01 - INORGANIC CHEMISTRY C01B - NON-METALLIC ELEMENTS

C01B3/384 - {the catalyst being continuously externally heated}

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J2219/32248 - Sheets comprising areas that are raised or sunken from the plane of the sheet
B01J2219/30475 - comprising catalytically active material
B01J2219/2495 - the plates being assembled interchangeably or in a disposable way
B01J23/894 - {with rare earths or actinides}
B01J2219/2496 - Means for assembling modules together, e.g. casings, holders, fluidic connectors

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02P - CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

Y02P20/52 - using catalysts, e.g. selective catalysts

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J2219/2485 - Metals or alloys

C - CHEMISTRY C01 - INORGANIC CHEMISTRY C01B - NON-METALLIC ELEMENTS

C01B2203/1614 - Controlling the temperature
C01B2203/085 - by electric heating

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J2219/2487 - Ceramics
B01J35/04 - Foraminous structures, sieves, grids, honeycombs
B01J19/249 - {Plate-type reactors}
B01J2219/2474 - Mixing means, e.g. fins or baffles attached to the plates
B01J2219/32251 - Dimples, bossages, protrusions
B01J2219/2482 - Catalytically active foils
B01J2219/2428 - Catalysts coated on the surface of the monolith channels

C - CHEMISTRY C01 - INORGANIC CHEMISTRY C01B - NON-METALLIC ELEMENTS

C01B2203/1064 - Platinum group metal catalysts

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J19/242 - {in series}
B01J2219/2454 - Plates arranged concentrically
B01J35/023 - {Catalysts characterised by dimensions, e.g. grain size}
B01J2219/32466 - comprising catalytically active material

C - CHEMISTRY C01 - INORGANIC CHEMISTRY C01B - NON-METALLIC ELEMENTS

C01B2203/0233 - the reforming step being a steam reforming step

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J2219/2479 - Catalysts coated on the surface of plates or inserts

C - CHEMISTRY C01 - INORGANIC CHEMISTRY C01B - NON-METALLIC ELEMENTS

C01B2203/1058 - Nickel catalysts

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DOE Contract Number:  

FC26-07NT43088

Resource Type:

Patent

Resource Relation:

Patent File Date: 2015 Dec 28

Country of Publication:

United States

Language:

English

Subject:

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CHEMISTRY