Chemical processors are configured to reduce mass, work in conjunction with solar concentrators, and/or house porous inserts in microchannel or mesochannel devices made by additive manufacturing. Methods of making chemical processors containing porous inserts by additive manufacturing are also disclosed.

Methods and apparatus for compact and easily maintainable waste reformation. Some embodiments include a rotary oven reformer adapted and configured to provide synthesis gas from organic waste. Some embodiments include a rotary oven with simplified operation both as to reformation of the waste, usage of the synthesized gas and other products, and easy removal of the finished waste products, preferably in a unit of compact size for use in austere settings. Yet other embodiments include Fischer-Tropsch reactors of synthesized gas. Some of these reactors include heat exchanging assemblies that provide self-cleaning effects, efficient utilization of waste heat, and ease of cleaning.

Methods for operating a high pressure olefin polymerization reactor include the steps of introducing an initiator stream containing ethylene and an initiator compound through an initiator nozzle into the reactor, introducing an olefin stream containing ethylene and an optional comonomer through an olefin nozzle into the reactor, and polymerizing ethylene and optionally the comonomer in the presence of the initiator stream in the reactor under high pressure polymerization conditions to produce an ethylene polymer. The amount of ethylene in the initiator stream is from 0.01 to 2 wt. % of the amount of ethylene in the olefin stream. An injection nozzle that can be used in conjunction with the high pressure reactor also is described.

Systems and methods are provided for production of carbon nanotubes and H.sub.2 using a reaction system configuration that is suitable for large scale production. In the reaction system, a substantial portion of the heat for the reaction can be provided by using a heated gas stream. Optionally, the heated gas stream can correspond to a heated H.sub.2 gas stream. By using a heated gas stream, when the catalyst precursors for the floating catalyst-chemical vapor deposition (FC-CVD) type catalyst are added to the gas stream, the gas stream can be at a temperature of 1000° C. or more. This can reduce or minimize loss of catalyst precursor material and/or deposition of coke on sidewalls of the reactor. Additionally, a downstream portion of the reactor can include a plurality of flow channels of reduced size that are passed through a heat exchanger environment, such as a shell and tube heat exchanger. This can provide cooling of the gas flow after catalyst formation to allow for carbon nanotube formation, while also reducing the Reynolds number of the flow sufficiently to provide laminar flow within the region where carbon nanotubes are formed.

A radial flow processing device includes a body with an inner chamber, a pair of inner and outer concentric tubes extending into the body, and a processing disk containing a central opening through which the inner tube extends, the disk being connected with the inner tube. The body has a top wall, a bottom wall, and at least one side wall which define the inner chamber. The bottom wall, top wall, or both, contain at least one opening through which at least one tube extends. A diameter of the inner tube is less than a diameter of the outer tube such that there is a space between both tubes, and a diameter of the disk is less than a width of the body.

Modular reactors comprising a chassis, reactor tubing and optionally a cover are disclosed. The chassis comprises a plurality of channels of different lengths into which a length of reactor tubing is placed to create the reactor portion of the flow reactor.

Methods and apparatus for compact and easily maintainable waste reformation. Some embodiments include a rotary oven reformer adapted and configured to provide synthesis gas from organic waste. Some embodiments include a rotary oven with simplified operation both as to reformation of the waste, usage of the synthesized gas and other products, and easy removal of the finished waste products, preferably in a unit of compact size for use in austere settings. Yet other embodiments include Fischer-Tropsch reactors of synthesized gas. Some of these reactors include heat exchanging assemblies that provide self-cleaning effects, efficient utilization of waste heat, and ease of cleaning.

Methods for operating a high pressure olefin polymerization reactor include the steps of introducing an initiator stream containing ethylene and an initiator compound through an initiator nozzle into the reactor, introducing an olefin stream containing ethylene and an optional comonomer through an olefin nozzle into the reactor, and polymerizing ethylene and optionally the comonomer in the presence of the initiator stream in the reactor under high pressure polymerization conditions to produce an ethylene polymer. The amount of ethylene in the initiator stream is from 0.01 to 2 wt. % of the amount of ethylene in the olefin stream. An injection nozzle that can be used in conjunction with the high pressure reactor also is described.

A micro-reactor for a reforming process has a cold side and a hot side opposite the cold side. Inlets are defined in the cold side, the inlets configured for receiving reagents. An outlet is defined in the cold side, the outlet configured for exiting reforming products. A reforming chamber is in the hot side, the reforming chamber having a catalyst, the reforming chamber configured for reforming the reagents into the reforming products, the reforming chamber including channels extending toward an end surface on the hot side of the reforming chamber, and a return plenum. A reagent path is from the inlets to the reforming chamber, the reagent path configured to feed the plurality of channels with reagents. A reforming product path is from the reforming chamber to the outlet, the reforming product path configured to receive products from the return plenum.

A structured catalyst for catalyzing an endothermic reaction of a feed gas to convert it to a product gas Including at least one macroscopic structure of an electrically conductive material and at least one connector attached to the at least one macroscopic structure, wherein the macroscopic structure supports a catalytically active material.