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.

A method of preheating a feed to a molten material reactor comprises heating a hydrocarbon feed in a first heat exchanger using a cooled product gas to produce a heated hydrocarbon feed stream, pyrolyzing at least a portion of the C.sub.2+ hydrocarbons in the heated feed stream in a pyrolysis reactor to produce a pyrolyzed hydrocarbon stream, and heating the pyrolyzed hydrocarbon stream in a second heat exchanger using a product gas to produce a pre-heated feed gas. The heated hydrocarbon feed stream comprises methane and one or more C.sub.2+ hydrocarbons.

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.

Disclosed herein is a rotary tube furnace configured to facilitate a chemical reaction between a solid mass and a gas in the furnace. The rotary tube furnace may comprise a reaction chamber extending through the furnace, the reaction chamber configured to control ingress and egress of each of the solid mass and the gas in the reaction chamber; a passage way configured to supply the solid mass to the reaction chamber; a passage way configured to supply the gas to the reaction chamber and circulate the gas through the reaction chamber; a heater providing heat to the reaction chamber and configured to control a reaction temperature in the reaction chamber; a magnetic field source in proximity to the reaction chamber for generating a magnetic field to one or more reaction zones of the reaction chamber; wherein the reaction chamber provides for mixing the solid mass and the gas.

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.

The invention relates to a process, unit and reaction system of low-carbon alkane dehydrogenation, which comprises the following steps: C3-C5 low-carbon alkane feed gas, together with CO and/or CO.sub.2 process gas, get into reactor after being preheated to 200-500° C., contact with a Cr—Ce—Cl/Al.sub.2O.sub.3 dehydrogenation catalyst, a Cu—Ce—Ca—Cl/Al.sub.2O.sub.3 thermal generating agent and thermal storage/support inert alumina balls, and convert to dehydrogenation products for 5-30 minutes under the conditions: temperature, 500-700° C., pressure, 10-100 kPa and weight hourly space velocity (WHSV), 0.1-5 hours.sup.−1. The products formed enter the downstream separation unit for separating out the low-carbon alkenes. The periodic regeneration process of the catalyst bed includes steam purging, hot air regenerating, bed heating, evacuating and reducing at 560 to 730° C. and 0.01 to 1 MPa. Each cycle needs about 10-70 minutes. With such dehydrogenation process, the reaction heat balance is moderated, and temperature gradient and reaction severity in the catalyst bed are reduced. As a consequence, the catalytic conversion, product selectivity, operation cycle and service life are improved. The system energy consumption is reduced.

A horizontal reactor equipped with a front cover and including a circular cylindrical rotating cage having multiple openings and rotated about a horizontal axis by a motor, a single horizontal rotary shaft mechanically connecting the rotating cage to the motor and extending towards the outside from the distal face of the housing, at least one bearing provided around the rotary shaft to hold it and guide it, and to support the weight of the rotating cage in cantilever, at least one removable basket having multiple openings and intended to be able to be introduced inside the rotating cage and to be removed through an open circular face of the rotating cage provided opposite the cover.

The invention relates to a process for production of copolymers, in particular for the polymerization of propylene, and another monomer chosen from a group comprising ethylene and a C4-C12 α-olefin in a horizontal stirred reactor comprising an agitated bed and several reaction zones for forming polymer particles.

A process for a continuous condensation reaction with feedstocks derived from bio-renewable resources, e.g., pine chemical derived feedstock, is disclosed. The process employs at least a multi-stage mixing reactor, selected from any of a multi-stage continuous stirred tank reactor (CSTR), a multi-stage horizontal continuous stirred tank reactor (HCSTR), or a continuous oscillating baffle reactor (COBR). The multi-stage mixing reactors are provided with a plurality of baffles for creating a mixing in a number of stages or cells created by the baffles, allowing the condensation reaction to proceed at a production rate at least twice that of a batch process with reactors of equivalent volume. The feedstocks derived from bio-renewable resources is selected from gum rosin, wood rosin, tall oil rosin and mixtures thereof; and polymeric fatty acids derived from bio-renewable resources such as tall oil.

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.