Systems and methods for molten media pyrolysis for the conversion of methane into hydrogen and carbon-containing particles are disclosed. The systems and methods include the introduction of seed particles into the molten media to facilitate the growth of larger, more manageable carbon-containing particles. Additionally or alternatively, the systems and methods can include increasing the residence time of carbon-containing particles within the molten media to facilitate the growth of larger carbon-containing particles.

Provided herein is a gas mixer for the safe mixing of a hydrocarbon containing gas with a gaseous oxidant. The gas mixer and method for mixing described includes a closed mixing vessel where bubbles of gas injected at the bottom of the vessel are mixed during their rise to the top of the vessel, forming a homogeneous mixture that can safely be removed. This simple design and method allows for safe mixing of gases and is applicable to catalytic oxidative processes such as oxidative dehydrogenation of paraffins where there is a risk of thermal runaway of reactions.

A continuous acoustic chemical microreactor system is disclosed. The system includes a continuous process vessel (CPV) and an acoustic agitator coupled to the CPV and configured to agitate the CPV along an oscillation axis. The CPV includes a reactant inlet configured to receive one or more reactants into the CPV, an elongated tube coupled at a first end to the reactant inlet and configured to receive the reactants from the reactant inlet, and a product outlet coupled to a second end of the elongated tube and configured to discharge a product of a chemical reaction among the reactants from the CPV. The acoustic agitator is configured to agitate the CPV along the oscillation axis such that the inner surface of the elongated tube accelerates the one or more reactants in alternating upward and downward directions along the oscillation axis.

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 system for processing a hydrocarbon feed has a final stage reactor and internal separator with cyclone that forms a substantially gas stream and a substantially non-gas stream. The substantially gas stream is sent directly from the final stage reactor and separator to further downstream processing.

The present invention relates to a reaction method for forming a layered structure of immiscible liquid-phase concentric layers within a rotary reactor and a reaction system including the layered structure, and may provide a basis capable of efficiently performing a multistage reaction in terms of time and space.

A continuous acoustic chemical microreactor system is disclosed. The system includes a continuous process vessel (CPV) and an acoustic agitator coupled to the CPV and configured to agitate the CPV along an oscillation axis. The CPV includes a reactant inlet configured to receive one or more reactants into the CPV, an elongated tube coupled at a first end to the reactant inlet and configured to receive the reactants from the reactant inlet, and a product outlet coupled to a second end of the elongated tube and configured to discharge a product of a chemical reaction among the reactants from the CPV. The acoustic agitator is configured to agitate the CPV along the oscillation axis such that the inner surface of the elongated tube accelerates the one or more reactants in alternating upward and downward directions along the oscillation axis.

A continuous acoustic chemical microreactor system is disclosed. The system includes a continuous process vessel (CPV) and an acoustic agitator coupled to the CPV and configured to agitate the CPV along an oscillation axis. The CPV includes a reactant inlet configured to receive one or more reactants into the CPV, an elongated tube coupled at a first end to the reactant inlet and configured to receive the reactants from the reactant inlet, and a product outlet coupled to a second end of the elongated tube and configured to discharge a product of a chemical reaction among the reactants from the CPV. The acoustic agitator is configured to agitate the CPV along the oscillation axis such that the inner surface of the elongated tube accelerates the one or more reactants in alternating upward and downward directions along the oscillation axis.

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.

A catalyst recovery system that includes a concentrated slurry production unit that concentrates a slurry extracted from a reactor main unit and continuously produces a concentrated slurry, a first discharge unit that discharges the concentrated slurry from the concentrated slurry production unit, a solidified slurry production unit that cools the concentrated slurry discharged from the concentrated slurry production unit, thereby solidifying the liquid medium within the concentrated slurry and producing a solidified slurry, and a recovery mechanism that recovers the solidified slurry from the solidified slurry production unit.