Chemical Reactor with Integrated Heat Exchanger, Heater, and High Conductance Catalyst Holder

Abstract

A chemical reactor that combines a pressure vessel, heat exchanger, heater, and catalyst holder into a single device is disclosed. The chemical reactor described herein reduces the cost of the reactor and reduces its parasitic heat losses. The disclosed chemical reactor is suitable for use in ammonia (NH.sub.3) synthesis.

Claims

1. A chemical reactor, comprising: a pressure vessel; a spiral heat exchanger disposed within the pressure vessel, the spiral heat exchanger comprising: a central region; a reactant-in spiral passageway configured to pass reactant from an inlet port of the spiral heat exchanger to the central region; and a reactant-out spiral passageway configured to pass reactant from the central region to an outlet port of the spiral heat exchanger; and a monolithic heater/catalyst holder component disposed within the pressure vessel and positioned in the central region of the spiral heat exchanger, wherein the monolithic heater/catalyst holder component comprises: a sheet metal or foil monolith with a honeycomb-like structure and which is configured to be heated by passing an electrical current through the monolith; and a catalyst coating on the honeycomb-like structure of the sheet metal or foil monolith.

2. (canceled)

3. (canceled)

4. (canceled)

5. (canceled)

6. The chemical reactor of claim 1, wherein an exit end of the reactant-in spiral passageway is located proximate an upstream side of the monolithic heater/catalyst holder component and an entrance end of the reactant-out spiral passageway is located proximate a downstream side of the monolithic heater/catalyst holder component.

7. (canceled)

8. (canceled)

9. (canceled)

10. (canceled)

11. The chemical reactor of claim 1, wherein the catalyst coating comprises a catalyst that promotes ammonia synthesis.

12. The chemical reactor of claim 1, wherein the catalyst of the catalyst coating is selected from the group consisting of powders of metal-decorated barium calcium aluminum oxide catalyst, powders of metal-decorated barium calcium boron oxide catalyst, and powders of metal-decorated barium calcium aluminum boron oxide catalyst.

13. The chemical reactor of claim 1, wherein the catalyst coating on the sheet metal or foil monolith is metal-decorated barium calcium aluminum oxide catalyst, metal-decorated barium calcium boron oxide catalyst, metal-decorated barium calcium aluminum boron oxide catalyst, or combinations thereof.

14. (canceled)

15. The chemical reactor of claim 1, wherein the entrance end of the reactant-in spiral passageway further comprises at least one pressure equalization port.

16. The chemical reactor of claim 15, wherein a first pressure equalization port is located at an axial end of the reactant-in spiral passageway and a second pressure equalization port is located at an opposite axial end of the reactant-in spiral passageway.

17. The chemical reactor of claim 15, wherein the at least one pressure equalization port is configured to pass reactant gas in the reactant-in spiral passageway into an insulated space located axially outside the spiral heat exchanger.

18. The chemical reactor of claim 17, wherein the insulated space is filled with compressible insulating material.

19. The chemical reactor of claim 18, wherein the compressible insulating material is selected from mineral wool, ceramic fiber, or a combination of both.

20. The chemical reactor of claim 16, wherein the first pressure equalization port is configured to pass reactant gas in the reactant-in spiral passageway into a first insulated space located axially above the spiral heat exchanger and the second pressure equalization port is configured to pass reactant gas in the reactant-in spiral passageway into a second insulated space located axially below the spiral heat exchanger.

21. The chemical reactor of claim 20, wherein the first insulated space and the second insulated space are filled with compressible insulating material.

22. The chemical reactor of claim 21, wherein the compressible insulating material is selected from mineral wool, ceramic fiber, or a combination of both.

23. The chemical reactor of claim 20, wherein each of the first insulated space and the second insulated space have a domed shape.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0014] Non-limiting and non-exhaustive embodiments of the disclosed chemical reactor, including the preferred embodiment, are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.

[0015] FIG. 1A is a radial cross section view of a combined heat exchanger, heater, and catalyst holder apparatus according to various embodiments described herein.

[0016] FIG. 1B is an axial cross section view of the combined heat exchanger, heater, and catalyst holder apparatus shown in FIG. 1A.

[0017] FIG. 2 is an axial cross section view of a combined heat exchanger, heater, and catalyst holder apparatus using a rod-shaped heater and an annular cylinder catalyst holder according to various embodiments described herein.

[0018] FIG. 3 is an axial cross section view of a combined heat exchanger, heater, and catalyst holder apparatus using a cylindrical heater and a metal monolith catalyst holder according to various embodiments described herein.

[0019] FIG. 4 is an axial cross section view of a combined heat exchanger, heater, and catalyst holder apparatus in which a metal monolith serves as both the heater and the catalyst holder according to various embodiments described herein.

DETAILED DESCRIPTION

[0020] Embodiments are described more fully below with reference to the accompanying Figures, which form a part hereof and show, by way of illustration, specific exemplary embodiments. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the disclosed embodiments. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense.

[0021] Described herein are various embodiments of a single chemical reactor apparatus including a pressure vessel containing a counterflow spiral heat exchanger, a heater, and a catalyst holder. The design is suitable for NH.sub.3 synthesis, but it can also be applied to other elevated temperature gas phase heterogeneous catalysis reactions. For purposes of describing the disclosed chemical reactor, reference will be made to use of the chemical reactor in the synthesis of NH.sub.3. However, the disclosed chemical reactor should not be construed as being only suitable for use in NH.sub.3 synthesis.

[0022] With reference to FIG. 1A, a radial cross section of an apparatus 100 according to various embodiments described herein is shown. A cylindrical pressure vessel 110 has a spiral heat exchanger 120 attached to its inner surface 111. Reactants gases enter the spiral heat exchanger cold side inlet 121 via a port 112 in the side of the pressure vessel 110 (also labeled “Reactants In” in FIG. 1A). The reactant gases acquire heat as they spiral inward through the spiral heat exchanger 120 to the central region 101 of that apparatus 100, which, as discussed in greater detail below, contains a heater and a catalyst holder (not shown in FIG. 1A).

[0023] The heater that can be disposed in the central region 101 as discussed in greater detail below provides heat to the reactants during apparatus warm-up and to make up for parasitic heat losses so they can be maintained at the desired temperature (typically 300-600° C.). The catalyst holder that can be disposed in the central region 101 as discussed in greater detail below is where NH.sub.3 synthesis occurs. The catalyst contained in the catalyst holder can be any suitable catalyst to promote the desired reaction. When the desired reaction is ammonia synthesis, the catalyst can include promoted iron ammonia synthesis catalyst, a metal-decorated barium calcium aluminum oxide catalyst, a metal-decorated barium calcium boron oxide catalyst, or a metal-decorated barium calcium aluminum boron oxide catalyst. More specifically, the catalyst can be granular promoted iron ammonia synthesis catalyst, granular or pellet metal-decorated barium calcium aluminum oxide catalyst, granular or pellet metal-decorated barium calcium boron oxide catalyst, granular or pellet metal-decorated barium calcium aluminum boron oxide catalyst, powders of metal-decorated barium calcium aluminum oxide catalyst dispersed on aluminum oxide granules, powders of metal-decorated barium calcium boron oxide catalyst dispersed on aluminum oxide granules, or powders of metal-decorated barium calcium aluminum boron oxide catalyst dispersed on aluminum oxide granules.

[0024] After passing through the heater and catalyst holder disposed in the central region 101, the product gases enter the hot side inlet 122 of the spiral heat exchanger 120. As the product gases spiral outward toward the cold side outlet 123 of the spiral heat exchanger 120 (also labeled “Product Out” in FIG. 1A), their heat is transferred to the incoming reactants. The cooled product gases exit the apparatus 100 and flow to other apparatus, not part of the chemical reactor described herein, that extract the NH.sub.3 from the product gas stream.

[0025] With reference to FIG. 1B, an axial cross-section view of the combined heat exchanger, heater, and catalyst holder apparatus 100 of FIG. 1A is shown. In this view it is seen that the top and bottom of the pressure vessel 110 are sealed with convex flanges 130. Reactant gases enter the reactor 100 via port 112 (shown on the right side of apparatus 100 in FIG. 1B). Pressure equalization ports 124 in the outer “Reactants In” spiral portion of the spiral heat exchanger 120 allow insulated spaces 131 positioned axially above and below the spiral heat exchanger 120 and under the convex flanges 130 to be pressurized with reactant gases. Locating the top and bottom pressure equalization ports 124 both at the beginning of the reactant inlet spiral of the spiral heat exchanger 120 ensures that they are at the same pressure as the incoming reactants, prevents continuous flow through them, and prevents them from supplying a path for the reactants to bypass the spiral heat exchanger 120, heater (not shown in FIG. 1B), and catalyst holder (not shown in FIG. 1B).

[0026] Equalizing the pressure in the insulated spaces 131 and the spiral heat exchanger 120 allows the apparatus 100 to operate under pressure without creating mechanical loads in the heat exchanger spirals of the spiral heat exchanger 120. This is advantageous because it allows the spiral walls of the spiral heat exchanger to be built from thinner sections of material, which reduces the apparatus cost and weight and increases the rate of heat exchange between the Reactant In and Product Out flows. For example, a spiral heat exchanger operating at 10 bar pressure that does not have inner and outer pressures equalized can require steel spirals 0.9 mm thick to bear the pressure-induced stresses, while one with pressure equalization could use 0.1 mm steel spirals because they only have to support the heat exchanger weight. Pressure equalization is also advantageous because it allows the use of highly effective compressible insulating materials, such as mineral wool and ceramic fiber, in the insulated spaced 130. If pressure equalization ports 124 are not utilized, a non-compressible insulation material can be used to transfer force from the catalyst holder (not shown in FIG. 1B) and spiral heat exchanger 120 to the walls of the pressure vessel 110. This can allow the spiral heat exchanger 120 to still be built from thinner sections of material in a manner similar to how thin inner tubes can be inflated to high pressures because the surrounding wheel, tire sidewalls, and tire tread provide mechanical strength.

[0027] In operation, cold reactant gas enters the apparatus 100 and cold product gas leaves the apparatus 100. Only the heater (not shown in FIG. 1B), catalyst holder (not shown in FIG. 1B) and regions adjacent to them at the central region 101 of the apparatus 100 are hot. This allows the outer walls of the pressure vessel 110 to remain at ambient temperature. The regions above and below the heater (not shown in FIG. 1B), catalyst holder (not shown in FIG. 1B), and spiral heat exchanger 120 are filled with an insulating material, which allows the top and bottom walls of the pressure vessel 110 to remain at ambient temperature. Keeping the walls of the pressure vessel 110 at ambient temperature is advantageous because it allows them to be built from thinner sections of lower cost materials with lower temperature limits. This reduces the cost and weight of the apparatus 100 compared to one with hot outer walls.

[0028] As referenced above, the central region 101 of the apparatus 100 shown in FIGS. 1A and 1B may include a heater and a catalyst holder. The specific configuration of the heater and catalyst holder can be varied. FIGS. 2-4 show various heater and catalyst holder configurations that can be used in the apparatus 100 shown FIGS. 1A and 1B.

[0029] With reference to FIG. 2, an axial cross-section view of one heater and catalyst holder configuration embodiment is shown. In this embodiment, the catalyst holder 240 is an annular cylinder with perforated inner walls 241 and perforated outer walls 242. The annular region 243 of the catalyst holder 240 is filled with granular NH.sub.3 catalyst. The perforated walls 241, 242 allow gases to flow radially through the catalyst filling the annular region 243. The heater 250 is rod-shaped and located at the center of the annular catalyst holder 240.

[0030] In operation, reactant gases enter the reactor 100 via the “Reactants In” port 112 (shown on the right side in FIG. 2). The reactant gas flows through the spiral channels of the spiral heat exchanger 120 toward the central region 101 of the reactor 100. As the reactants flow toward the central region 101 of the apparatus 100, they acquire heat from the products flowing through the spiral heat exchanger 120 toward the edge of the apparatus 100. At the point where the “Reactants In” traveling inwardly through the spiral heat exchanger 120 near the outer side of the catalyst holder 240, the spiral heat exchanger 120 terminates and joints a set of tubes 244 that pass through the annular catalyst holder 240 to deliver heated reactants to the open center of the catalyst holder 240. The reactants impinge on the heater 250 located there, allowing them to be heated if desired. The reactants then flow from the central region 101 (optionally heated via heater 250) of the catalyst holder 240 through the catalyst holder 240, where the NH.sub.3 synthesis occurs. The product gases (unused reactants+NH.sub.3 reaction product) are collected in the region 245 just outside the annular catalyst holder 240 (also labeled “Product Out” in FIG. 2). They then enter the “Product Out” spiral of the spiral heat exchanger 120. As the product gases flow through the “Product Out” spirals, their heat is transferred to the incoming reactants flowing through the “Product In” spirals. The product gases exit the apparatus 100 via the “Product Out” port 113 (shown on the left side of FIG. 2).

[0031] FIG. 3 illustrates another embodiment of the catalyst holder and heater configuration. Reactants enter the apparatus 100 and flow through the spiral heat exchanger 120 toward the central region 101 of the apparatus 100, acquiring heat from the product flow as they do so. At the central region 101 of the apparatus 100, the reactants pass axially through a heater 350 that adds supplemental heat to the reactants if desired. Nonlimiting examples of the heater include honeycomb monoliths, finned spiral rod heaters, or finned serpentine rod heaters, each heated by an electric current.

[0032] The fully heated reactants then flow axially into the catalyst holder 340 located axially downstream from the heater 350. The catalyst holder 340 is a honeycomb-like sheet metal or foil monolith coated with NH.sub.3 synthesis catalyst, similar to metal monolith automotive catalytic converters. The reactants interact with the catalyst to make NH.sub.3, and the resulting product gas and unused reactants enter the “Product Out” spiral of the spiral heat exchanger 120. As the reactants flow toward the outer edge of the apparatus 100 via the “Product Out” spirals of the spiral heat exchanger 120, their heat is transferred to the incoming reactants flowing inwardly through the spiral heat exchanger 120.

[0033] FIG. 4 illustrates still another embodiment of the catalyst holder and heater configuration. Gases flow through the apparatus 100 in the same manner as described with respect to FIG. 3. In this embodiment, however, the heater and catalyst holder are combined into a single metal monolith 440. The metal monolith 440 is fabricated from thin sheet metal or foil and is coated with a NH.sub.3 synthesis catalyst. The metal monolith 440 is configured so that an electrical current can be passed through it to heat it and the attached catalyst. This is advantageous because it allows the monolith 440 to replace the separate heater 350 depicted in FIG. 3, reducing the apparatus parts count. It is also advantageous because direct bonding of the catalyst to the monolith 440 allows the catalyst to be heated very rapidly, reducing the time required for the apparatus to start producing NH.sub.3.

[0034] From the foregoing, it will be appreciated that specific embodiments of the disclosed chemical reactor have been described herein for purposes of illustration, but that various modifications may be made without deviating from the scope of the disclosed chemical reactor. Accordingly, the disclosed chemical reactor is not limited except as by the appended claims.

[0035] Although the technology has been described in language that is specific to certain structures and material, it is to be understood that the chemical reactor defined in the appended claims is not necessarily limited to the specific structures and material described. Rather, the specific aspects are described as forms of implementing the claimed chemical reactor. Because many embodiments of the chemical reactor can be practiced without departing from the spirit and scope of the chemical reactor, the chemical reactor resides in the claims hereinafter appended.