The invention relates to Quench box assembly comprising quench pipe and quench box, to mix quench gas and vapor-liquid effluent from previous catalyst bed to achieve equilibrium temperature before entering the next bed. The quench pipe is in the form of ring having aperture while quench box consists of swirling section and a mixing chamber. The swirling section consists of inclined baffles to provide swirling action to incoming stream and the turbulence created by the swirling action increases the heat transfer rate thus requiring the smaller reactor volume to attain equilibrium temperature. The perforated plate being open from all the sides allowing the liquid to flow uniformly from all directions thus providing uniform distribution on the distributor tray. Hence, eliminates the requirement of rough liquid distributor before the distribution tray.

The invention relates to a chemical reactor and reformer tubes for reforming a first feed stream comprising a hydrocarbon gas and steam. The chemical reactor comprises a shell with a heat source and one or more reformer tubes. The reformer tube is arranged to house catalyst material and is arranged to being heated by the heat source. The reformer tube comprises a first inlet for feeding said first feed stream into a first reforming reaction zone of the reformer tube, and a feed conduct arranged to allow a second feed stream into a second reforming reaction zone of the reformer tube. The second reforming reaction zone is positioned downstream of the first reforming reaction zone. The feed conduct is configured so that the second feed stream is only in contact with catalyst material in the second reforming reaction zone. The invention also relates to a process of producing CO rich synthesis gas at low S/C conditions.

In at least one embodiment, a reactor includes a reactor body. A first internal heat exchanger and a second internal heat exchanger are within the reactor body. One or more slabs of one or more static inserts are disposed between the first internal heat exchanger and the second internal heat exchanger. A plurality of flow paths is defined between the plurality of flow channels of the first internal heat exchanger and the plurality of flow channels of the second internal heat exchanger. Each static insert is configured to rotate or translate a flow path so that on average, the existing boundary layers formed in the first heat exchanger are moved away from the channel walls by a distance of equal or greater than the thickness of the boundary layers at the exit of the first heat exchanger.

In a cooled axial flow converter, in which process gas passes from an outer annulus via a catalyst bed, wherein the process gas is converted to a product, to an inner centre tube, the catalyst bed comprises at least one module comprising at least one catalyst layer. Feed means are arranged to provide a flow of process gas from the outer annulus to an inlet part of one or more modules, and collector means are arranged to provide a flow of product stream of converted process gas, which has passed axially down the catalyst bed of one or more of the modules to the centre tube. At least one of the one or more modules comprises one or more cooling plates arranged to be cooled by a cooling fluid.

The invention relates to a process for producing hydrogen from a light hydrocarbon source, in which a synthesis gas is generated by steam methane reforming after desulfurization and optionally pre-reforming of the feedstock. The synthesis gas is enriched with hydrogen by steam conversion of carbon monoxide, and is subsequently purified in a pressure swing adsorption unit to give a pure H.sub.2 product and a residual gas mixture containing CH.sub.4, CO, H.sub.2 and CO.sub.2; in accordance with the invention, the conversion step is performed in a cooled reactor in which the heat of the conversion reaction is transferred to a fluid which feeds the burners of the reformer, or to the gas for reforming.

Systems and methods are provided for improving the operation of groups of reverse flow reactors by operating reactors in a regeneration portion of the reaction cycle to have improved flue gas management. The flue gas from reactor(s) at a later portion of the regeneration step can be selectively used for recycle back to the reactors as a diluent/heat transport fluid. The flue gas from a reactor earlier in a regeneration step can be preferentially used as the gas vented from the system to maintain the desired volume of gas within the system. This results in preferential use of higher temperature flue gas for recycle and lower temperature flue gas for venting from the system. This improved use of flue gas within a reaction system including reverse flow reactors can allow for improved reaction performance while reducing or minimizing heat losses during the regeneration portion of the reaction cycle.

In one embodiment, a reactor includes a reactor body and a reactor head. The reactor head has a reactor head body and one or more inlets disposed tangentially to the reactor head body. In one embodiment, a polymerization process for forming polymer includes introducing in a first direction a stream including a monomer. The stream and a catalyst system are flowed in a second direction through at least one internal heat exchanger. The second direction is substantially orthogonal to the first direction. The reaction zone includes at least one internal heat exchanger. At least a portion of the monomer of the stream is polymerized in the reaction zone to produce a polymer product. The polymer product is recovered from the reaction zone.

An ammonia synthesis converter for small production units which provides full access for routine maintenance and catalyst replacement while providing adequate catalyst pressure drop to ensure kinetic performance and reduce heat leak from the catalyst beds. A shell has a removable top head and an annular basket is removably mounted in the shell. First and second catalyst beds are disposed in the annular zone of the basket for axial down-flow in series. A quench gas is introduced into effluent from the first catalyst bed and the resulting mixture into a top of the second catalyst bed. A feed-effluent interchanger in the inner basket zone is adapted to receive effluent from the second catalyst bed and indirectly heat a feed to the first catalyst bed. Also, methods of operating and servicing the converter.

A method for producing hydrogen includes flowing a first gas along a bayonet flow path of a steam methane reformer (SMR) to produce a first product, including flowing the first gas through a foam disposed along the bayonet flow path; providing the first product produced in the SMR to an input of a water gas shift (WGS) reaction channel defined within a reaction tube of a WGS reactor; and flowing a second gas including the first product through the WGS reaction channel to produce a second product. Flowing the second gas includes flowing the second gas across a heat transfer material disposed in the WGS reaction channel to reduce the temperature of the flowing second gas; and flowing the second gas across a WGS catalyst disposed in the reaction channel.

A system and method for producing olefin via dry reforming and olefin synthesis in the same vessel, including providing feed including methane and carbon dioxide to the vessel, converting methane and carbon dioxide in the vessel into syngas (that includes hydrogen and carbon monoxide) via dry reforming in the vessel, and cooling the syngas via a heat exchanger in the vessel. The method includes synthesizing olefin from the syngas in the vessel, wherein the olefin includes ethylene, propylene, or butene, or any combinations thereof.