The present invention provides a highly effective method of continuous reactions in a heat exchanger reactor using a flexible turbulator (2). The flexible turbulator (2) present in the tube of the reactor assembly provides efficient mixing and reaction of the reactants in the reactor. The tube and shell assembly provides better heat transfer by transfer of heat through the temperature gradient across the tube (3) wall. The shell fluid (8) can be cold or hot as required depending on whether the reaction is exothermic or endothermic. The reactants are passed through the inlet (6) and allowed to mix and react in the tube (3), the mixing and reaction is facilitated by flexible turbulator and the final product is received through the outlet. The process can be repeated to achieve desired final product. Progress of the reaction is measured by thermal sensors present inside the reactor. The data is processed through a highly specialized computer software and output about progress of reaction is monitored.

A membrane reactor includes a catalyst layer, a separation membrane, and a buffer layer. The catalyst layer contains a catalyst for promoting a conversion reaction from a feed gas containing hydrogen and carbon oxide to a liquid fuel. The separation membrane is permeable to water vapor which is a byproduct of the conversion reaction. The buffer layer is disposed between the separation membrane and the catalyst layer, and permeable to the water vapor toward the separation membrane.

A method for enhancing the heat transfer performance of a vertical tubular reactor by adding heat transfer elements inside the reactor tubes. Such heat transfer elements have two or more substantially curved legs of equal length with no cross fins, each with a foot that engages the inside wall of the tube, and can optionally have two or more substantially curved sub-legs that do not engage the wall of the tube.

A bayonet reactor including a catalytic reactor in the form of an annular structured packing is provided with increased surface area for the transfer of heat between annulus gas and return gas, an increased coefficient of heat transfer between the annulus and return gases, and a reduced overall pressure drop relative to conventional reactors. The reactors of the present technology can enable intensified catalytic processing.

A baffle (i.e., tube support) for use in a shell-and-tube heat exchange reactor, such as, for example, an ethylene oxide (EO) reactor, is provided that accommodates reduced tube pitch, and thus more catalyst packed tubes can be inside the reactor. The baffle, which can be referred to herein as a corrugated grid support, includes a plurality of corrugated stainless steel strips which sit into each other and form a grid pattern having tube openings. Each tube opening is configured to permit a catalyst packed tube to be inserted therein, while allowing a sufficient open area along the shell side of the tube to permit coolant to flow through the reactor.

The present invention provides a highly effective method of removal of gases from the chemical reactor (01) by use of a suction unit employed near the inlet, outlet or both ends of the chemical reactor. The suction of entrapped air from the reaction mixture helps avoid fluctuation in the temperature or pressure requirement or formation of other by-products in the reaction mixture.

A method for enhancing the heat transfer performance of a vertical tubular reactor by adding heat transfer elements inside the reactor tubes. Such heat transfer elements have two or more substantially curved legs of equal length with no cross fins, each with a foot that engages the inside wall of the tube, and can optionally have two or more substantially curved sub-legs that do not engage the wall of the tube.

A method for producing (meth)acrolein by vapor-phase catalytic oxidation of propylene or isobutylene in a multitubular reactor including a plurality of reaction tubes, the reaction tubes each including a reaction zone filled with a catalyst including molybdenum oxide and a cooling zone filled with an inert substance, wherein a temperature of a heat medium that flows outside the cooling zone is lower than a temperature of a heat medium that flows outside the reaction zone, and wherein the inert substance includes an inert substance having a major-axis length that is equal to or more than 1.7 times a major-axis length of the catalyst. A method for producing (meth)acrylic acid in which (meth)acrolein thus produced is converted to (meth)acrylic acid by vapor-phase catalytic oxidation.

A bayonet reactor including a catalytic reactor in the form of an annular structured packing is provided with increased surface area for the transfer of heat between annulus gas and return gas, an increased coefficient of heat transfer between the annulus and return gases, and a reduced overall pressure drop relative to conventional reactors. The reactors of the present technology can enable intensified catalytic processing.

A reactor (1) for thermochemical reactions is provided comprising a reactor shell (13) having an inlet (2) and an outlet (3). Solid catalyst (16) is provided in reaction zones (4a, 4b, 4c) in which at least a portion of reactants entering the reactor (1) undergo a thermochemical reaction. A heat exchange medium is provided in heat exchange zones such that heat is exchanged between the reaction zones (4a, 4b, 4c) and the heat exchange medium. One or more hollow inserts (11) at least partially extend through the reaction zones (4a, 4b, 4c). The hollow inserts (11) are configured to form a flow path to either: divert a portion of the reactants from the reactor inlet (2) or from one reaction zone to a different reaction zone; or divert a portion of the heat exchange medium from one heat exchange zone to a different heat exchange zone.