Provided herein are methods and systems for converting natural gas, and specifically methane, into higher-value oxycarbon products, such as methanol, methyl formate, and formic acid. The natural gas is introduced into an aqueous solution with hydroxyl radicals and reacted in ambient conditions to form the desired products in the presence of a metal catalyst. The methods described herein overcome the over-activation dilemma of prior art methods that lead to the formation of undesirable carbon oxide compounds. Methods and apparatus for forming hydrogen peroxide via electrolysis and for forming hydroxyl radicals from the hydrogen peroxide via reaction with ferrous ions are also provided.

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.

A structured packing module for a gas phase reactor has a structured packing with a central axis extending along a longitudinal direction, and may further include an inner tube extending coaxially with the structured packing and along the longitudinal direction. The structured packing includes a plurality of corrugated sheets, each arranged circumferentially around the central axis and having a first end and a second end spaced apart from each other along the longitudinal direction. The corrugated sheets are arranged to radially overlap with each other such that corrugations of adjacently disposed corrugated sheets are arranged in a crisscross relationship. The structured packing module includes a gas flow path comprising at least one inter-sheet gas flow path defined between the adjacently disposed corrugated sheets.

A reactor for carrying out catalytic reactions. The reactor includes a reactor component optionally arranged on a central rod in a reactor tube. The reactor component can have fluid ducts for directing fluid flow through the reactor. The fluid ducts are effective for increasing heat transfer in the reactor. The reactor component can further have a washer attached to a top or bottom surface for directing fluid flow.

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.

An apparatus includes an inlet, an outlet, and a sheet disposed proximate a heat transfer surface, wherein the sheet is oriented in a sheet plane that is displaced from a plane of the heat transfer surface by an angle of at least 10 degrees. The apparatus also includes a plurality of tabs attached to the sheet, the tabs lying in respective tab planes, wherein the tab planes and the sheet plane intersect forming respective intersections. The intersections of the tab planes and the sheet plane are substantially parallel. The intersections of the tab planes and the sheet plane are at an angle of less than 88 to the heat transfer surface, and the plurality of tabs collectively form channels directing a fluid passing from the inlet to the outlet to impinge the heat transfer surface.

A genre of media is presented for use with a reactor vessel and for the purpose of immobilizing small particles, often catalytic in nature. The media can include a number of ferromagnetic active wafers stacked together and separated by non-ferromagnetic separator portions, such that when in the presence of a magnetic field and magnetic-particle-containing fluid, at least some of the gaps between active wafers captures and suspends magnetic particles.

A method for enabling gas exchange and chemical reactions with one or more liquid streams contained in a reactive process vessel are provided. One or more exchange layers within the process vessel can be composed of both collector media and releaser media. The exchange layers allow elements to facilitate increased performance of vessel operations by promoting gas component mixing and diffusion. Improved rates of gas component exchange mean less coking and more gas components available for reaction.

A chemical flow reactor comprising: a housing having an inlet and an outlet; at least one heat exchange pipe extending through the interior of the housing; a space defined between the interior surface of the housing and the outer surface of Gas Flow the at least one pipe, said space being in fluid communication with the inlet and the outlet; and a plurality of plates stacked within said space forming a stacked plate assembly between the inlet and the outlet, each plate comprising at least one hole through which the at least one pipe extends such that the at least one pipe extends through the stacked plate assembly. An active chemical, such as a catalyst, is disposed on each plate.

An apparatus is provided for use in a chemical process, which includes at least one metal tube or flow channel having at least one surface with at least one organic linker attached thereto. The at least one organic linker has first and second molecular groups, wherein the first molecular group is configured to bind to the at least one surface, and wherein the second molecular group is configured to bind to at least one compound that functions as an adsorbent or catalyst in the chemical process in order to attach the at least one compound to the at least one surface. Methods of constructing an apparatus for use in a chemical process are also described and claimed.