STEAM REFORMING HEATED BY RESISTANCE HEATING

Abstract

A reactor system for carrying out steam reforming of a feed gas comprising hydrocarbons, including: a structured catalyst arranged for catalyzing steam reforming of a feed gas including hydrocarbons, the structured catalyst including a macroscopic structure of electrically conductive material, the macroscopic structure supporting a ceramic coating, wherein the ceramic coating supports a catalytically active material; a pressure shell housing the structured catalyst; heat insulation layer between the structured catalyst and the pressure shell; at least two conductors electrically connected to the macroscopic structure and to an electrical power supply placed outside the pressure shell, wherein the electrical power supply is dimensioned to heat at least part of the structured catalyst to a temperature of at least 500° C. by passing an electrical current through the macroscopic structure. Also, a process for steam reforming of a feed gas comprising hydrocarbons.

Claims

1. A reactor system for carrying out steam reforming of a feed gas comprising hydrocarbons, said reactor system comprising: a structured catalyst arranged for catalyzing steam reforming of said feed gas comprising hydrocarbons, said structured catalyst comprising a macroscopic structure of electrically conductive material, said macroscopic structure supporting a ceramic coating, wherein said ceramic coating supports a catalytically active material; a pressure shell housing said structured catalyst, said pressure shell comprising an inlet for letting in said feed gas and an outlet for letting out product gas, wherein said inlet is positioned so that said feed gas enters said structured catalyst in a first end of said structured catalyst and said product gas exits said structured catalyst from a second end of said structured catalyst; a heat insulation layer between said structured catalyst and said pressure shell; and at least two conductors electrically connected to said structured catalyst and to an electrical power supply placed outside said pressure shell, wherein said electrical power supply is dimensioned to heat at least part of said structured catalyst to a temperature of at least 500° C. by passing an electrical current through said macroscopic structure, wherein said at least two conductors are connected to the structured catalyst at a position on the structured catalyst closer to said first end of said structured catalyst than to said second end of said structured catalyst, and wherein the structured catalyst is constructed to direct an electrical current to run from one conductor substantially to the second end of the structured catalyst and return to a second of said at least two conductors.

2. A reactor system according to claim 1, wherein the pressure shell has a design pressure of between 5 and 30 bar.

3. A reactor system according to claim 1, wherein the pressure shell has a design pressure of between 30 and 200 bar.

4. A reactor system according to claim 1, wherein the resistivity of the macroscopic structure is between 10.sup.−5 Ω.Math.m and 10.sup.−7 Ω.Math.m.

5. A reactor system according to claim 1, where each of the at least two conductors are led through the pressure shell in a fitting so that the at least two conductors are electrically insulated from the pressure shell.

6. A reactor system according to claim 5, wherein said pressure shell further comprises one or more inlets close to or in combination with at least one fitting in order to allow a cooling gas to flow over, around, close to, or inside at least one conductor within said pressure shell.

7. A reactor system according to claim 1, wherein the reactor system further comprises an inner tube in heat exchange relationship with but electrically insulated from the structured catalyst, said inner tube being adapted to withdraw a product gas from the structured catalyst so that the product gas flowing through the inner tube is in heat exchange relationship with gas flowing through the structured catalyst.

8. A reactor system according to claim 1, wherein the connection between the structured catalyst and said at least two conductors is a mechanical connection, a welded connection, a brazed connection or a combination thereof.

9. A reactor system according to claim 1, wherein the macroscopic structure is an extruded and sintered structure or a 3D printed and sintered structure.

10. A reactor system according to claim 1, wherein the structured catalyst comprises an array of macroscopic structures electrically connected to each other.

11. A reactor system according to claim 1, wherein said structured catalyst has electrically insulating parts arranged to increase the length of a principal current path between said at least two conductors to a length larger than the largest dimension of the structured catalyst.

12. A reactor system according to claim 1, wherein said structured catalyst has at least one electrically insulating part arranged to direct a current through said structured catalyst in order to ensure that for at least 70% of the length of said structured catalyst, a current density vector of the principal current path has a non-zero component value parallel to the length of said structured catalyst.

13. A reactor system according to claim 1, wherein said macroscopic structure has a plurality of parallel channels, a plurality of non-parallel channels and/or a plurality of labyrinthic channels.

14. A reactor system according to claim 1, wherein the reactor system further comprises a bed of a second catalyst material upstream said structured catalyst within said pressure shell.

15. A reactor system according to claim 12, wherein said reactor system further comprises a third catalyst material in the form of catalyst pellets, extrudates or granulates loaded into the channels of said structured catalyst.

16. A reactor system according to claim 1, further comprising a bed of fourth catalyst material placed within the pressure shell and downstream the structured catalyst.

17. A reactor system according to claim 1, wherein the material of the macroscopic structure is chosen as a material arranged to generate a heat flux of 500 to 50000 W/m.sup.2 by resistance heating of the material.

18. A reactor system according to claim 1, wherein the structured catalyst comprises a first part arranged to generate a first heat flux and a second part arranged to generate a second heat flux, where the first heat flux is lower than the second heat flux, and where the first part is upstream the second part.

19. A reactor system according to claim 1, wherein said reactor system further comprises a control system arranged to control the electrical power supply to ensure that the temperature of the gas exiting the pressure shell lies in a predetermined range and/or to ensure that the conversion of hydrocarbons in the feed gas lies in a predetermined range and/or to ensure the dry mole concentration of methane lies in a predetermined range and/or to ensure the approach to equilibrium of the steam reforming reaction lies in a predetermined range.

20. A reactor system according to claim 1, wherein the structured catalyst within said reactor system has a ratio between the area equivalent diameter of a horizontal cross section through the structured catalyst and the height of the structured catalyst in the range from 0.1 to 2.0.

21. A reactor system according to claim 1, wherein the height of the reactor system is between 0.5 and 7 m.

22. A process for carrying out steam reforming of a feed gas comprising hydrocarbons in a reactor system comprising a pressure shell housing a structured catalyst arranged to catalyze steam reforming of a feed gas comprising hydrocarbons, said structured catalyst comprising a macroscopic structure of an electrically conductive material, said macroscopic structure supporting a ceramic coating, where said ceramic coating supports a catalytically active material and wherein said reactor system is provided with heat insulation between said structured catalyst and said pressure shell; said process comprising the following steps: pressurizing a feed gas comprising hydrocarbons to a pressure of at least 5 bar, supplying said pressurized feed gas to said pressure shell through an inlet positioned so that said feed gas enters said structured catalyst in a first end of said structured catalyst; allowing the feed gas to undergo steam reforming reaction over the structured catalyst and outletting a product gas from said pressure shell, wherein said product gas exits said structured catalyst from a second end of said structured catalyst; supplying electrical power via electrical conductors connecting an electrical power supply placed outside said pressure shell to said structured catalyst, allowing an electrical current to run through said macroscopic structure, thereby heating at least part of the structured catalyst to a temperature of at least 500° C., wherein said at least two conductors are connected to the structured catalyst at a position on the structured catalyst closer to said first end of said structured catalyst than to said second end of said structured catalyst, and wherein the structured catalyst is constructed to direct an electrical current to run from one conductor substantially to the second end of the structured catalyst and return to a second of said at least two conductors.

23. A process according to claim 22, further comprising the step of pressurizing the feed gas upstream the pressure shell to a pressure of between 5 and 30 bar.

24. A process according to claim 22, further comprising the step of pressurizing said feed gas upstream said pressure shell to a pressure of between 30 and 200 bar.

25. A process according to claim 22, wherein the temperature of the feed gas let into the reactor system is between 200° C. and 700° C.

26. A process according to claim 22, wherein the macroscopic structure is heated so that the maximum temperature of the macroscopic structure lies between 500° C. and 1300° C.

27. A process according to claim 22, further comprising the step of inletting a cooling gas through an inlet through the pressure shell close to or in combination with at least one fitting in order to allow a cooling gas to flow over, around, close to, or inside at least one conductor within said pressure shell.

28. A process according to claim 22, wherein the space velocity evaluated as flow of gas relative to the geometric surface area of the structured catalyst is between 0.6 and 60 Nm.sup.3/m.sup.3/h or between 700 Nm.sup.3/m.sup.3/h and 70000 Nm.sup.3/m.sup.3/h when evaluated as flow of gas relative to the occupied volume of the structured catalyst.

Description

SHORT DESCRIPTION OF THE FIGURES

[0115] FIG. 1a shows a cross section through an embodiment of the inventive reactor system with a structured catalyst comprising an array of macroscopic structures, in a cross section;

[0116] FIG. 1b shows the reactor system of FIG. 1a with a part of the pressure shell and heat insulation layer removed;

[0117] FIG. 2 is an enlarged view of a part of the reactor system;

[0118] FIGS. 3a and 3b show schematic cross sections through an embodiment of the inventive reactor system comprising a structured catalyst;

[0119] FIGS. 4 and 5 show an embodiment of a structured catalyst with an array of macroscopic structures as seen from above and from the side, respectively;

[0120] FIG. 6 shows an embodiment of the structured catalyst used in the reactor system of the invention;

[0121] FIGS. 7, and 8 show embodiments of a structured catalyst with connectors;

[0122] FIG. 9a shows an embodiment of a structured catalyst for use in the reactor system of the invention;

[0123] FIG. 9b shows the current density of the structured catalyst shown in FIG. 9a as a function of the electrical effect transferred to the structured catalyst;

[0124] FIG. 10 a schematic drawing of a cross-section through structured catalyst with electrically insulating parts;

[0125] FIGS. 11a and 11b show temperature and conversion profiles as a function of electrical effect transferred to the structured catalyst;

[0126] FIGS. 12a and 12b show simulation results for temperatures and gas composition along the length of the structured catalyst;

[0127] FIG. 13 shows the required maximum temperature within the reactor system of the invention as a function of the pressure; and

[0128] FIG. 14 is a graph of the approach to equilibrium (ΔT.sub.app,SMR) of the steam methane reforming reaction for different gas flow rates over a structured catalyst.

DETAILED DESCRIPTION OF THE FIGURES

[0129] Throughout the Figures, like reference numbers denote like elements.

[0130] FIG. 1a shows a cross section through an embodiment of a reactor system 100 according to the invention. The reactor system 100 comprises a structured catalyst 10, arranged as an array of macroscopic structures 5. Each macroscopic structure 5 in the array is coated with a ceramic coating impregnated with catalytically active material. The reactor system 100 moreover comprises conductors 40, 40′ connected to a power supply (not shown in the Figures) and to the structured catalyst 10, viz. the array of macroscopic structures. The conductors 40, 40′ are led through the wall of a pressure shell 20 housing the structured catalyst and through insulating material 30 on the inner side of the pressure shell, via fittings 50. The conductors 40′ are connected to the array of macroscopic structures 5 by conductor contact rails 41.

[0131] In an embodiment, the electrical power supply supplies a voltage of 70V and a current of 800 A. In another embodiment, the electrical power supply supplies a voltage of 170V and a current of 2000 A. The current is led through electrical conductors 40, 40′ to conductor contact rails 41, and the current runs through the structured catalyst 10 from one conductor contact rail 41, e.g. from the conductor contact rail seen to the left in FIG. 1a, to the other conductor contact rail 41, e.g. the conductor contact rail seen to the right in FIG. 1a. The current can be both alternating current, and e.g. run alternating in both directions, or direct current and run in any of the two directions.

[0132] The macroscopic structures 5 are made of electrically conductive material. Especially preferred is the alloy kanthal consisting of aluminum, iron and chrome. The ceramic coating, e.g. an oxide, coated onto the structure catalysts 5 is impregnated with catalytically active material. The conductors 40, 40′ are made in materials like iron, aluminum, nickel, copper, or alloys thereof.

[0133] During operating, a feed gas enters the reactor system 100 from above as indicated by the arrow 11 and exits the reactor system from the bottom thereof as indicated by the arrow 12.

[0134] FIG. 1b shows the reactor system 100 of FIG. 1a with a part of the pressure shell 20 and heat insulation 30 layer removed and FIG. 2 is an enlarged view of a part of the reactor system 100. In FIGS. 1b and 2 the connections between conductors 40′ and conductor contact rails 41 are shown more clearly than in FIG. 1a. Moreover, it is seen that the conductors 40 are led through the walls of the pressure shell in a fitting 50, and that the one conductor 40 is split up into three conductors 40′ within the pressure shell. It should be noted, that the number of conductors 40′ may be any appropriate number, such as smaller than three or even larger than three.

[0135] In the reactor system shown in FIGS. 1a, 1b and 2, the conductors 40, 40′ are led through the wall of a pressure shell 20 housing the structured catalysts and through insulating material 30 on the inner side of the pressure shell, via fittings 50. Feed gas for steam reforming is inlet into the reactor system 100 via an inlet in the upper side of the reactor system 100 as shown by the arrow 11, and reformed gas exists the reactor system 100 via an outlet in the bottom of the reactor system 100 as shown by the arrow 12. Moreover, one or more additional inlets (not shown in FIGS. 1a to 2) advantageously exist close to or in combination with the fittings 50. Such additional inlets allow a cooling gas to flow over, around, close to, or inside at least one conductor within the pressure shell to reduce the heating of the fitting. The cooling gas could e.g. be hydrogen, nitrogen, steam, carbon dioxide, or mixtures thereof. The temperature of the cooling gas at entry into the pressure shell may be e.g. about 100° C.

[0136] In the reactor system 100 shown in FIGS. 1a to 2, inert material (not shown in FIGS. 1a-2) is advantageously present between the lower side of the structured catalyst 10 and the bottom of the pressure shell. Moreover, inert material is advantageously present between the outer sides of the structured catalyst 10 of macroscopic structures 5 and the insulating material 30. Thus, one side of the insulating material 30 faces the inner side of the pressure shell 20 and the other side of the insulating material 30 faces the inert material. The inert materiel is e.g. ceramic material and may be in the form of pellets. The inert material assists in controlling the pressure drop across the reactor system 100 and in controlling the flow of the gas through the reactor system 100, so that the gas flows over the surfaces of the structured catalyst 10.

[0137] FIGS. 3a and 3b show schematic cross sections through an embodiment of the inventive reactor system 100′, 100″ comprising a structured catalyst 10a. The structured catalyst 10a may consist of a single macroscopic structure with ceramic coating supporting catalytically active material or it may contain two or more macroscopic structures. Each of the reactor systems 100′, 100″ comprises a pressure shell 20 and a heat insulation layer 80 between the structured catalyst 10a and the pressure shell 20. In FIGS. 3a and 3b, the inert material 90 is indicated by hatching. Inert material 90 can be used to fill the gap between the structured catalyst 10a and the heat insulation layer or the pressure shell 20. In FIGS. 3a and 3b, the inert material 90 is indicated by dotted area; the inert material 90 may be in any appropriate form, e.g. in the form of inert pellets, and it is e.g. of ceramic material. The inert material 90 assists in controlling the pressure drop through the reactor system and in controlling the flow of the gas through the reactor system. Moreover, the inert material typically has a heat insulating effect.

[0138] From FIGS. 3a and 3b it is seen that the reactor systems 100′, 100″ further comprise an inner tube 15 in heat exchange relationship with the structured catalyst 10a. The inner tube 15 is adapted to withdraw a product gas from the structured catalyst 10a so that the product gas flowing through the inner tube or tubes is in heat exchange relationship with the gas flowing through the structured catalyst; however, the inner tube 15 is electrically insulated from the structured catalyst 10a by either heat insulation 80, inert material 90, a gap, or a combination. This is a layout which is denoted a bayonet reactor system. In this layout the product gas within the inner tube assists in heating the process gas flowing over the macroscopic structure. In the layouts shown in FIGS. 3a and 3b, the feed gas enters the reactor system 100′, 100″ through an inlet as indicated by the arrow 11, and enters into the structured catalyst 10a at a first end 101a thereof, as indicated by the arrows 13. During the passage of the feed gas through the structured catalyst 10a, it undergoes the steam reforming reaction. The gas exiting from a second end 102a of the structured catalyst 10a is at least partly reformed. The at least partly reformed gas flows exiting from the second end 102a of the structured catalyst 10a enters into the inner tube 15 as indicated by the arrows 14, and exits the inner tube through an outlet of the pressure shell, as indicated by the arrows 12. Even though the inert material 80 is present between the inner tube 15 and the structured catalyst 10a, some heat transfer will take place from the gas within the inner tube 15 and the gas within the structured catalyst 10a or upstream the structured catalyst 10a. In the embodiments shown in FIGS. 3a and 3b, the feed gas flow downwards through the structured catalyst 10a, from a first end 101a of the structured catalyst towards a second end 102a thereof, and subsequently upwards through the inner tube 15; however, it is conceivable that the configuration was turned upside-down so that the feed gas would flow upwards through the structured catalyst 10a and downwards through the inner tube 15. In this case, the lower end of the structured catalyst would be the first end, and the upper end of the structured catalyst would be the second end.

[0139] FIGS. 4 and 5 show an embodiment of a structured catalyst comprising an array of macroscopic structures as seen from above and from the side, respectively. FIG. 4 shows a structured catalyst 10 comprising an array of macroscopic structure 5 seen from above, viz. as seen from the arrow 11 in FIGS. 1a and 1b. The array has 6 rows, viz. 1a, 1b, 1c, 1d, 1e, and 1f, of five macroscopic structures 5. The macroscopic structures 5 in each row are connected to its neighboring macroscopic structure (s) in the same row and the two outermost macroscopic structures in each row are connected to a conductor contact rail 41. The neighboring macroscopic structure 5 in a row of macroscopic structures are connected to each other by means of a connection piece 3.

[0140] FIG. 5 shows the structured catalyst 10 having an array of macroscopic structures 5 of FIG. 4 seen from the side. From FIG. 5, it can be seen that each macroscopic structure 5 extends longitudinally perpendicular to the cross section seen in FIG. 4. Each macroscopic structure 5 has a slit 60 cut into it along its longitudinal direction (see FIG. 5). Therefore, when energized by the power source, the current enters the array of macroscopic structures 5 via a conductor contact rail 41, is led through the first macroscopic structure 5 downwards until the lower limit of the slit 60 and is subsequently led upwards towards a connection piece 3. The current is led via a corresponding zigzag path, downwards and upwards, through each macroscopic structure 5 in each row 1a-1f of macroscopic structures 5 in the array 10. This configuration advantageously increases the resistance over the structured catalyst 10.

[0141] FIG. 6 shows a structured catalyst 10′ according to the invention in a perspective view. The structured catalyst 10′ comprises a macroscopic structure that is coated with a ceramic coating impregnated with catalytically active material. Within the structured catalyst are channels 70 extending along the longitudinal direction (shown by the arrow indicate ‘h’ in FIG. 6) of the macroscopic structure 5; the channels are defined by walls 75. In the embodiment shown in FIG. 6, the walls 75 define a number of parallel, square channels 70 when seen from the direction of flow as indicated by the arrow 12. The structured catalyst 10′ has a substantially square perimeter when seen from above, defined by the edge lengths e1 and e2. However, the perimeter could also be circular or another shape.

[0142] The walls 75 of the structured catalyst 10′ are of extruded material coated with a ceramic coating, e.g. an oxide, which has been coated onto the macroscopic structure. In the Figures, the ceramic coating is not shown. The ceramic coating is impregnated with catalytically active material. The ceramic coating and thus the catalytically active material are present on every walls within the structured catalyst 10′ over which the gas flow flows during operation and interacts with the heated surface of the structured catalyst and the catalytically active material.

[0143] Thus, during use in a reactor system for steam reforming, a hydrocarbon feed gas flows through the channels 70 and interacts with the heated surface of the structured catalyst and with the catalytically active material supported by the ceramic coating.

[0144] In the structured catalyst 10′ shown in FIG. 6 a slit 60 has been cut into the structured catalyst 10′. This slit 60 forces a current to take a zigzag route, in this instance downwards and subsequently upwards, within the macroscopic structure thereby increasing the current path and thus the resistance and consequently the heat dissipated within the macroscopic structure. The slit 60 within the macroscopic structure may be provided with embedded insulating material in order to ensure that no current flows in the transverse direction of the slit 60.

[0145] The channels 70 in the structured catalyst 5 are open in both ends. In use of the structured catalyst in a reactor system, a hydrocarbon feed gas flows through the unit, in the direction shown by arrows 11 and 12 in FIGS. 1a and 1b, and gets heated via contact with the walls 75 of the channels 70 and by heat radiation. The heat initiates the desired steam reforming process. The walls 75 of the channels 70 may e.g. have a thickness of 0.5 mm, and the ceramic coating coated onto the walls 75 may e.g. have a thickness of 0.1 mm. Even though the arrows 11 and 12 (see FIGS. 1a and 1b) indicate that the flow of the hydrocarbon feed gas is down-flow, the opposite flow direction, viz. an up-flow, is also conceivable.

[0146] FIG. 7 shows the structured catalyst 5 of FIGS. 1a and 1b in a perspective view and with connectors 7 attached. The connectors 7 each connects a part of the structured catalyst 10′ to a conductor 40. The conductors 40 are both connected to a power supply (not shown). Each of the connectors 7 are connected to an upper part of the structured catalyst. When the conductors 40 are connected to a power supply, an electrical current is led to the corresponding connector 7 via the conductor and runs through the structured catalyst 10′. The slit 60 hinders the current flow in a transverse direction (horizontal direction of FIG. 7) throughout its lengths along the height h of the structured catalyst 10′. Therefore, the current runs in a direction downwards as seen in FIG. 7 in the part of the structured catalyst along the slit 60, subsequently it runs transversely to the longitudinal direction below the slit 60 as seen in FIG. 7 and finally the current runs upwards in the longitudinal direction of the structured catalyst to the other connector 7. The connectors 7 in FIG. 7 are mechanically fastened to the structured catalyst by means of i.a. mechanical fastening means such as screws and bolts. However, additional or alternative fastening means are conceivable. In an embodiment, the electrical power supply generates a voltage of 3V and a current of 400 A.

[0147] The connectors 7 are e.g. made in materials like iron, aluminum, nickel, copper, or alloys thereof.

[0148] As mentioned, the structured catalyst 10′ is coated with a ceramic coating, such as an oxide, supporting the catalytically active material. However, the parts of the structured catalyst 10′ which are connected to the connectors 7 should not be coated with an oxide. Instead, the macroscopic structure of the structured catalyst should be exposed or connected directly to the connectors 7 in order to obtain a good electrical connection between the macroscopic structure and the connector.

[0149] When the connectors 7 and thus the conductors 40 are connected to the same end of the structured catalyst 5, viz. the upper end as seen in FIG. 7, the gas entering into a reactor system housing the structured catalyst 10′ would be able to cool the connectors 7 and the conductors 40. For instance, the hydrocarbon gas entering into such a reactor system would have a temperature of 400° C. or 500° C. and would thus keep the connectors 7 and conductors 40 from reaching temperatures much higher than this temperature.

[0150] FIG. 8 shows another embodiment of a structured catalyst 10′ with connectors 7′″. The structured catalyst 10′ is e.g. the structured catalyst as shown in FIG. 6. Each of the connectors 7′″ has three holes at an upper side thereof for connection to conductors (not shown). A piece of electrically insulating material 61 is inside the slit 60 (see FIG. 6) of the structured catalyst 10′.

[0151] FIG. 9a shows an embodiment of a structured catalyst 10″ for use in the reactor system of the invention. FIG. 9a shows the structured catalyst 10″ in a perspective view. It can be seen that the structured catalyst 10″ has a single vertical slit 60 along the longitudinal axis of the catalyst 10″ as shown in FIG. 9a. The single vertical slit 60 extends from the top of the structured catalyst 10″ towards the bottom thereof, along about 90% of the length of the structured catalyst. The single vertical slit 60 can be seen as parting the structured catalyst 10″ into two halves. Each of these two halves has five horizontal slits 65. The vertical slit 60 and the horizontal slits 65 function to direct the current in a zig-zag route through the structured catalyst.

[0152] FIG. 9b shows the current density of the structured catalyst 10″ shown in FIG. 9a as a function of the electrical effect transferred to the structured catalyst 10″. FIG. 9b is the result of a multiphysics computational fluid dynamics simulations in Comsol software of the current distribution of the structure in FIG. 9a. In FIG. 9b the structured catalyst 10″ is seen from the side. Two conductors (not shown in FIG. 9b) are connected to the upper end on the left side of the structured catalyst 10″. As illustrated by the intensity of the current density, as depicted on the scale in the right part of FIG. 9b, when a power source is connected to the structured catalyst 10″, a current runs from the upper end thereof in zig-zag form, due to the horizontal slits, to the bottom of the structure catalyst 10″, to the back thereof, viz. into the paper as seen in FIG. 9b, and subsequently upwards in zig-zag form towards the second conductor. The temperature of the structured catalyst 10″ depends upon the current density throughout the structured catalyst 10″. It can be seen in FIG. 9b, that the current density is highest at the end points of horizontal slits 65 into the structured catalyst 10″. These points are the points where the current path turns direction, i.e. where the current through the structured catalyst 10″ is forced or directed in another direction. Moreover, it can be deduced that the current density vector of the principal current path has a non-zero component value parallel to the length of said structured catalyst for more than 80% of the structure. In conclusion, it is clear from FIG. 9b that the principal current path can be controlled in the structured catalyst. This feature gives control of the temperature profile inside the structured catalyst.

[0153] FIG. 10 a schematic drawing of a cross-section through structured catalyst with electrically insulating parts. FIG. 10 is a schematic drawing of a cross-section through a structured catalyst 10′″ of the invention, with electrically insulating parts 61′. The electrically insulating parts are shown as hatched parts in FIG. 10. In the embodiment shown in FIG. 10, three pieces of electrically insulating parts 61′ intersects the structured catalyst 10′″ in most of the longitudinal direction thereof. Conductors 7 are connected to the upper side of the structured catalyst 10′″ as seen in FIG. 10. During use of the structured catalyst 10′″, the conductors 7 are connected to a power supply and a hydrocarbon feed gas is brought into contact with the structured catalyst 10″′. Thus, current runs from the first conductor through the structured catalyst 10′″ in a zigzag direction, viz. downwards from the first conductor and around the lower side of the first electrically insulating part 61′, subsequently upwards and around the upper side of the middle electrically insulating part 61′, then downwards again and around the lower side of the third electrically insulating part 61′ and finally upwards to the second conductor 7. It should be noted that any appropriate number of electrically insulating parts 61′ is conceivable. The electrically insulating parts 61′ are solid, electrically insulating material, e.g. glass, and they are provided in cuts or slits in the macroscopic structure. The electrically insulating parts 61′ ensures that the parts of the macroscopic structure on the sides electrically insulating parts 61′ are kept from each other. It should be noted, that in this embodiment, as in all the embodiments of the invention, the direction of flow of gas may be the same as the direction of the current through the structured catalyst, or it may be different. In the embodiment of FIG. 10, the direction of flow of gas is e.g. from the upper side of the structured catalyst 10′″ towards the bottom of the structured catalyst 10′″; thus, the flow of current only the same as the direction of the flow of gas as some parts of the structured catalyst 10′″, whilst the direction of the current is transverse to the direction of the flow of gas at some parts and opposite (upwards) in some parts.

[0154] FIGS. 11a and 11b shows temperature and conversion profiles as a function of electrical effect transferred to the structured catalyst. FIG. 11a is the result of a laboratory test of bench scale reactor system having a length of 12 cm and a volume 108 cm.sup.3 of the structured catalyst as defined by the outer walls/sides thereof and configuration as depicted in FIG. 6 where Cu conductors has been welded to the first 2 cm of the monolith on opposing sides in the first end. The pressure of the pressure shell was 3.5 bar, the temperature of the feed gas inlet into the reactor system was about 200° C. The composition of the feed gas was 31.8% CH.sub.4, 2.4% H.sub.2, 65.8% H.sub.2O and the total gas flow was 102.2 NI/h. It should be noted, that the energy balance is substantially better in a larger scale than in the small scale experimental conditions behind the graphs of FIG. 11a, due to high energy loss in this relative small scale. However, it is clear from FIG. 11a that with increasing power, both the conversion of methane and the temperature increases. The temperature reaches above 900° C. and the methane convercion reaches above 98%.

[0155] FIG. 11b shows a similar experiment as described above, but with a pressure of 21 bar. Again, it is clear from FIG. 11b that with increasing power, both the conversion of methane and the temperature increases. The temperature reaches above 1060° C. and the methane conversion reaches above 95%.

[0156] FIGS. 12a and 12b show simulation results for temperatures and gas composition along the length of structured catalyst. A single channel of a structured catalyst is simulated. The length of the structured catalyst of this simulation, and thus of the single channel, is 10 cm. The conditions within the pressure shell/structured catalyst/channel is: [0157] Pressure: 29 barg [0158] T inlet: 466° C. [0159] Total flow: 30 NI/h [0160] Composition of the feed gas inlet into the reactor/channel: 31.8% methane, [0161] 8.8% hydrogen, 2.3% carbon dioxide, and 57.1% steam.

[0162] In FIG. 12a, the temperature of the wall of the channel is indicated by Tw and the temperature in the center of the channel is indicated by Tc. Tw and Tc are read from the scale to the right of the graphs. The methane conversion is indicated by Cc and is read from the scale to the left of the graphs.

[0163] From FIG. 12a it is seen that the temperature of the wall of a channel in the structured catalyst increases continuously along almost all of the length of the structured catalyst. The temperature is about 480° C. at the first end of the structured catalyst (z=0 cm) and about 1020° C. at the second end of the structured catalyst (z=10 cm). The increase of temperature is steepest the first 10% of the structured catalyst, and only in the last few percent of the length of the structured catalyst, the temperature does not change much. Thus, when the current turns around at the second end of the structured catalyst, from going downwards to upwards in the FIGS. 1-9a, the temperature of the walls of the channels of the structured catalyst does not change substantially for increasing z-values. However, FIG. 12a also shows that the temperature in the center of the channel keeps on increasing along the whole length of the structured catalyst. It should be noted, though, that the temperature in the center of the channel remains substantially constant for the first 5-7% of the length of the structured catalyst. This is due to the fact that the gas inlet into the structured catalyst cools the structured catalyst in the vicinity of the first end thereof and due to thermal energy transport delay from the wall to the center of the channel.

[0164] In FIG. 12a, the conversion of methane in the center of the channel of the structured catalyst is also shown. It can be seen that the conversion is close to zero for the first 10-12% of the length of the channel, and that the conversion subsequently increases monotonously and reaches a value of about 85%. As noted above, small scale reactors and simulations thereof provide for less than optimal numbers, and that considerably higher conversion is achievable in a real scale reactor system. However, the simulation provides information on the tendencies of the conversion rate and temperature throughout the structured catalyst.

[0165] FIG. 12b shows the partial pressures of the principle active gasses within the channel of the structured catalyst of FIG. 12a. From FIG. 12b it is clear that the partial pressures of steam and methane diminish considerably along the length of the channel of the structured catalyst, whilst the partial pressures of hydrogen and carbon monoxide increase considerably. Moreover, the partial pressure of carbon dioxide increases slightly along the length of the structured catalyst, but decreases towards the highest temperatures where the reverse water gas shift reaction is thermodynamically favored.

[0166] FIG. 13 shows the required maximum temperature within the reactor system of the invention as a function of the pressure for pressures of about 30 bar to about 170 bar during steam reforming of a feed gas consisting of 30.08% CH.sub.4, 69.18% H.sub.2O, 0.09% H.sub.2, 0.45% CO.sub.2, 0.03% Ar, 0.02% CO, 0.15% N.sub.2 to a methane conversion of 88% at a 10° C. approach to the steam methane reforming equilibrium. The required maximum temperature increases with pressure due to Le Chatelier's principle. This shows that the high temperatures which can be used in the current invention allows for using pressures which are significantly higher than the pressures used in a traditional SMR, where the external heating of the tubes prohibit the temperature exceeding ca. 950° C. A temperature of 950° C. corresponds to 27 barg in FIG. 13. In a reactor system of the invention, a maximum temperature of e.g. 1150° C. can be used which allows for a pressure of up to 146 barg with the same conversion of methane as indicated above.

[0167] FIG. 14 is a graph of the approach to equilibrium (ΔT.sub.app,SMR) of the steam methane reforming reaction for different gas flow rates through the structured catalyst. FIG. 14 shows that for a given gas flow rate through the structured catalyst, the approach to equilibrium at the entry into a reactor system housing the structured catalyst, is in the range 160-175° C., because the feed gas is far from equilibrium. When the hydrocarbon gas flows through the structured catalyst, the approach to equilibrium is reduced due to the catalytic reactions. FIG. 14 shows the approach to equilibrium (ΔT.sub.app,SMR) for gas flow rates from 10000 Nm.sup.3/h to 200000 Nm.sup.3/h. For the lowest gas flow rate, 10000 Nm.sup.3/h, the approach to equilibrium becomes less than 10° C. at about 13% of the reactor system length. Here, the reactor system length is seen as outer height of the structured catalyst in the direction of the flow, so that the reactor system length of the structured catalyst 10 is about 1 h in the embodiment of FIG. 6. For higher gas flow rates, the approach to equilibrium is higher the higher the gas flow rate, so that for a gas flow rate of 200000 Nm.sup.3/h, the approach to equilibrium reaches a minimum value just below 80° C.

[0168] A general trend in all the curves in the FIG. 14 is that the approach to equilibrium is continuously decreasing from the entry into the structured catalyst until a pseudo equilibrium is reached, where the heat added and the heat consumed roughly equal each other. The approach to equilibrium from this stage is substantially constant or has a slightly increasing development due to the overall increasing temperature of the reactor system. For e.g. the flow rate 150 000 Nm.sup.3/h, the approach to equilibrium goes below 60° C. at about 80% of the reactor system length, but subsequently increases to about 60° C.

[0169] It should be noted, that even though the structured catalysts shown in the figures are shown as having channels with a square cross section, as seen perpendicular to the z axis, any appropriate shape of the cross sections of the channels is conceivable. Thus, the channels of the structured catalyst could alternatively be e.g. triangular, hexagonal, octagonal, or circular, where triangular, square, and hexagonal shapes are preferred.

EXAMPLES

[0170] While the invention has been illustrated by a description of various embodiments and examples while these embodiments and examples have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept.

[0171] All the examples described below relate to compact reactor systems. This is possible due to the reactor systems comprise compact structured catalysts in the form of compact macroscopic supports having a high thermal flux when powered by a power source. It is moreover to be noted, that the dimensions of the structured catalysts may be chosen relatively freely, so that the structured catalyst may be almost cubic in outer shape or it may be wider than its height.

[0172] The examples all describe operation conditions with high pressure, ranging from 28 bar to 182 bar. Such high pressures are made possible by the configuration of the reactor system since the structured catalyst within the reactor system has high thermal flux upon powering by a power source, is to some extent thermally insulated from the pressure shell, and the pressure drop through the structured catalyst is very low compared to an SMR. The structured catalyst will obtain the highest temperature within the reactor system, while the pressure shell will have a significantly lower temperature due to the thermal insulation between the structured catalyst and the pressure shell. Ideally, the temperature of the pressure shell will not exceed 500° C. When product gas with a high pressure is needed, such as 30 bar or above, the product gas exiting the reactor system can in many cases be used directly, without the use of compressors. This is due to the possibility of pressurizing the feed gas upstream the reactor system of the invention. Pressurizing the feed gas will require less energy than the product gas as the volume of the feed is lower than the product gas as the steam reforming reaction has a net production of molecules. Additionally, one of the feed gas constituents may be pumped which requires significantly less energy compared to gas compression.

[0173] In all the examples described below, the feed gas enters the reactor system and flows through the structured catalyst housed therein. When the heat insulation layer of the reactor system is a heat insulating material, the heat insulating material typically makes up most of the space between the structured catalyst and the pressure shell along the walls of the pressure shell so that the feed gas is forced to flow along walls of the macroscopic structure on its way through the pressure shell.

[0174] The examples below (except for the comparative example) all relate to a reactor system with a structured catalyst. The structured catalysts described in these examples comprise one or more macroscopic structures. The one or more macroscopic structures of the examples below all support a ceramic coating supporting catalytically active material. Advantageously, substantially all the surface of the macroscopic structure supports the ceramic coating supporting the catalytically active material; however, at connections points, e.g. between two adjacent macroscopic structures or between a macroscopic structure and a conductor, the macroscopic structure may be free from ceramic coating in order to facilitate connection between a conductor and the macroscopic structure.

Example 1

[0175] An example calculation of the process of the invention is given in Table 1 below. A feed gas is fed to the reactor system of the invention. The feed gas entering the reactor system is pressurized to a pressure of 28 kg/cm.sup.2.Math.g and has a temperature of 500° C. Inside the reactor system, a structured catalyst with nine macroscopic structures having a square cross section are placed in an array and each macroscopic structure has a size of 0.53 times 0.53 times 2.3 meter. Each macroscopic structure additionally has 17778 channels with a square cross section having a side or edge length of 0.32 cm. Each macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 5 times 5 channels are formed. The clusters are individually insulated from the neighboring cluster, except from the ends, so that the current path through the macroscopic structure is a zigzag path. A current of 200 A and a voltage of ca. 5.5 kV are applied to each macroscopic structure in the reactor system of the invention in order to heat the structured catalyst and thus the gas passing through the structured catalyst, corresponding to a power supplied in the structured catalysts of 9899 kW.

[0176] The reactor system in the current configuration could have an overall internal diameter of the reactor system of 3.2 m and a total internal height of 5.5 m when the reactor system is made as a cylindrical reactor system with spherical heads. In this specific configuration, the macroscopic structures are placed in a square orientation having a diagonal length of 2.3 m. In all the examples described herein, except for the comparative example, inert material is placed around the structured catalyst to close the gap to the insulation material, adjacent to the pressure shell. The insulation material in example 1 has a cylindrical form with an internal diameter of 2.5 m and a thickness of 0.35 m.

[0177] During the passage of the feed gas through the reactor system, the feed gas is heated by the structured catalyst and undergoes steam reforming to a product gas having an exit temperature of 963° C.

TABLE-US-00001 TABLE 1 Size of macroscopic structure: Edge size [m] 0.53 Height [m] 2.3  Number of macroscopic structures 9   Total volume of structured catalyst [L] 5888     Structured catalyst height/diagonal length [—] 1.02 Feed gas Product gas T [° C.] 500 963 P [kg/cm.sup.2 g] 27.97 27.47 CO2 [Nm.sup.3/h] 168 727 N2 [Nm.sup.3/h] 26 26 CH4 [Nm.sup.3/h] 2630 164 H2 [Nm.sup.3/h] 590 8545 CO [Nm.sup.3/h] 1 1907 H2O [Nm.sup.3/h] 8046 5022 Total flow [Nm.sup.3/h] 11461 16391 ΔT.sub.app, SMR [° C.] 10 Power [kW] 9899     Heat flux [kW/m.sup.2] 2.2  Space velocity [Nm.sup.3/m.sup.3/h] 1950    

Example 2

[0178] An example calculation of the process of the invention is given in Table 2 below. A feed gas is fed to the reactor system of the invention. The feed gas entering the reactor system is pressurized to a pressure of 28 kg/cm.sup.2.Math.g and has a temperature of 500° C. Inside the reactor system, a structured catalyst in the form of 1 macroscopic structure having a square cross section is placed which has a size of 0.4 times 0.4 times 0.35 meter. The macroscopic structure additionally has 10000 channels with a square cross section having a side or edge length of 0.32 cm. The macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 5 times 5 channels are formed. The clusters are individually insulated from the neighboring cluster, except from the ends, so that the current path through the macroscopic structure is a zigzag path. A current of 200 A and a voltage of ca. 500 V are applied to the macroscopic structure in the reactor system of the invention in order to heat the structured catalyst and thus the gas passing through the structured catalyst, corresponding to a power deposited in the structured catalyst of 99 kW.

[0179] The reactor system in the current configuration could have an overall internal diameter of the reactor system of 1.2 m and a total internal height of 1.5 m when the reactor system is made as a cylindrical reactor system with spherical heads. In this specific configuration, the structured catalyst has a diagonal length of 0.6 m. Inert material is placed around the structured catalysts to close the gap to the insulation material which has an internal diameter of 0.6 m and a thickness of 0.3 m.

[0180] During the passage of the feed gas through the reactor system, the feed gas is heated by the structured catalyst and undergoes steam reforming to a product gas having an exit temperature of 963° C.

TABLE-US-00002 TABLE 2 Size of macroscopic structure: Edge size [m] 0.4 Height [m]  0.35 Number of macroscopic structures 1   Total volume of structured catalyst [L] 55.4  Structured catalyst height/diagonal length [—]  0.61 Feed gas Product gas T [° C.] 500 963 P [kg/cm.sup.2 g] 27.97 27.47 CO2 [Nm.sup.3/h] 1.7 7.3 N2 [Nm.sup.3/h] 0.3 0.3 CH4 [Nm.sup.3/h] 26.3 1.6 H2 [Nm.sup.3/h] 5.9 85.4 CO [Nm.sup.3/h] 0 19.1 H2O [Nm.sup.3/h] 80.5 50.2 Total flow [Nm.sup.3/h] 114.7 163.9 ΔT.sub.app, SMR [° C.] 10 Power [kW] 99   Heat flux [kW/m.sup.2] 2.2 Space velocity [Nm.sup.3/m.sup.3/h] 2071   

Example 3

[0181] An example calculation of the process of the invention is given in Table 3 below. A feed gas is fed to the reactor system of the invention. The feed gas entering the reactor system is pressurized to a pressure of 97 bar, viz. 97 kg/cm.sup.2.Math.g and has a temperature of 500° C.

[0182] Inside the reactor system, a structured catalyst comprising nine macroscopic structures having a square cross section are placed in an array and each macroscopic structure has a size of 0.53 times 0.53 times 2.3 meter. Each macroscopic structure additionally has 17778 channels with a square cross section having a side or edge length of 0.32 cm. Each macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 5 times 5 channels are formed. The clusters are individually insulated from the neighboring cluster, except from the ends so that the current path through the macroscopic structure is a zigzag path. A current of 200 A and a voltage of ca. 5.5 kV are applied to each macroscopic structure in the reactor system of the invention in order to heat the structured catalyst and thus the gas passing through the structured catalyst, corresponding to a power deposited in the structured catalyst of 9899 kW.

[0183] The reactor system in the current configuration could have an overall internal diameter of the reactor system of 3.2 m and a total internal height of 5.5 m when the reactor system is made as a cylindrical reactor system with spherical heads. In this specific configuration, the macroscopic structures are placed in a square orientation having a diagonal length of 2.3 m. Inert material is placed around the structured catalyst to close the gap to the insulation material which has an internal diameter of 2.5 m and a thickness of 0.35 m.

[0184] During the passage of the feed gas through the reactor system, the feed gas is heated by the structured catalyst and undergoes steam reforming to a product gas having an exit temperature of 1115° C. It is seen from Table 3 that the total flows of the feed gas and the product gas are lower in Example 3 compared to Example 1.

[0185] Since the product gas exiting the reactor system is pressurized to a pressure of 97 bar, no compressors will be needed downstream the reactor system when a high pressure product gas is requested. This reduces the overall cost of a plant with a reactor system of the invention.

TABLE-US-00003 TABLE 3 Size of macroscopic structure: Edge size [m]  0.53 Height [m] 2.3 Number of macroscopic structures 9   Total volume of structured catalyst [L] 5888    Structured catalyst height/diagonal length [—]  1.01 Feed gas Product gas T [° C.] 500 1115 P [kg/cm.sup.2 g] 96.97 96.47 CO2 [Nm.sup.3/h] 111 510 N2 [Nm.sup.3/h] 23 23 CH4 [Nm.sup.3/h] 2337 143 H2 [Nm.sup.3/h] 372 7354 CO [Nm.sup.3/h] 1 1796 H2O [Nm.sup.3/h] 7111 4518 Total flow [Nm.sup.3/h] 9955 14344 ΔT.sub.app, SMR [° C.] 10 Power [kW] 9899    Heat flux [kW/m.sup.2] 2.2 Space velocity [Nm.sup.3/m.sup.3/h] 1691   

Example 4

[0186] An example calculation of the process of the invention is given in Table 3 below. A feed gas is fed to the reactor system of the invention. The feed gas entering the reactor system is pressurized to a pressure of 28 bar, viz. 28 kg/cm.sup.2.Math.g and has a temperature of 500° C.

[0187] Inside the reactor system, a structured catalyst comprising 25 macroscopic structures having a square cross section are placed in an array and each macroscopic structure has a size of 0.24 times 0.24 times 0.9 meter. Each macroscopic structure additionally has 3600 channels with a square cross section having a side or edge length of 0.33 cm in length. Each macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 10 times 10 channels are formed. The clusters are individually insulated from the neighboring cluster, except from the ends, so that the current path through the macroscopic structure is a zigzag path. A current of 1500 A and a voltage of ca. 260 V are applied to each macroscopic structure in the reactor system of the invention in order to heat the structured catalyst and thus the gas passing through the structured catalyst, corresponding to a power deposited in the structured catalyst of 9899 kW.

[0188] The reactor system in the current configuration could have an overall internal diameter of the reactor system of 2.3 m and a total internal height of 3.2 m when the reactor system is made as a cylindrical reactor system with spherical heads. In this specific configuration, the macroscopic structures are placed in a square orientation having a diagonal length of 1.7 m. Inert material is placed around the structured catalyst to close the gap to the insulation material which has an internal diameter of 1.8 m and a thickness of 0.25 m.

[0189] During the passage of the feed gas through the reactor system, the feed gas is heated by the structured catalyst and undergoes steam reforming to a product gas having an exit temperature of 963° C. It is seen from Table 4 that the structured catalyst of Example 4 is somewhat smaller than the one used in Examples 1 and 3 due to the higher current. The total flows of the feed gas and the product gas correspond to the flows of Example 1.

TABLE-US-00004 TABLE 4 Size of macroscopic structure: Edge size [m]  0.24 Height [m] 0.9 Number of macroscopic structures 25   Total volume of structured catalyst [L] 1324    Structured catalyst height/diagonal length [—]  0.54 Feed gas Product gas T [° C.] 500 963 P [kg/cm.sup.2 g] 27.97 27.47 CO2 [Nm.sup.3/h] 168 727 N2 [Nm.sup.3/h] 26 26 CH4 [Nm.sup.3/h] 2630 164 H2 [Nm.sup.3/h] 590 8545 CO [Nm.sup.3/h] 1 1907 H2O [Nm.sup.3/h] 8046 5022 Total flow [Nm.sup.3/h] 11461 16391 ΔT.sub.app, SMR [° C.] 10 Power [kW] 9899    Heat flux [kW/m.sup.2] 9.0 Space velocity [Nm.sup.3/m.sup.3/h] 8653   

Example 5

[0190] An example calculation of the process of the invention is given in Table 4 below. A feed gas is fed to the reactor system of the invention. The feed gas entering the reactor system is pressurized to a pressure of 182 bar and has a temperature of 500° C.

[0191] Inside the reactor system, a structured catalyst comprising nine macroscopic structures having a square cross section are placed in an array and each macroscopic structure has a size of 0.53 times 0.53 times 2.3 meter. Each macroscopic structure additionally has 17778 channels with a square cross section having a side or edge length of 0.32 cm. Each macroscopic structure has slits parallel to the longitudinal direction thereof, so that clusters of 5 times 5 channels are formed. The clusters are individually insulated from the neighboring cluster, except from the ends, so that the current path through the macroscopic structure has a zigzag path. A current of 200 A and a voltage of ca. 5.5 kV are applied to each macroscopic structure in the reactor system of the invention in order to heat the structured catalyst and thus the gas passing through the structured catalyst, corresponding to a power deposited in the structured catalyst of 9899 kW.

[0192] The reactor system in the current configuration could have an overall internal diameter of the reactor system of 3.2 m and a total internal height of 5.5 m when the reactor system is made as a cylindrical reactor system with spherical heads. In this specific configuration, the macroscopic structures are placed in a square orientation having a diagonal length of 2.3 m. Inert material is placed around the structured catalyst to close the gap to the insulation material which has an internal diameter of 2.5 m and a thickness of 0.35 m.

[0193] During the passage of the feed gas through the reactor system, the feed gas is heated by the structured catalyst and undergoes steam reforming to a product gas having an exit temperature of 1236° C. The total flows of the feed gas and the product gas are lower than the total flows of the gasses in Examples 1 and 4.

[0194] Since the product gas exiting the reactor system is already pressurized to a pressure of 181 bar, it is suited for being input into e.g. a hydrotreater of a refinery plant without further pressurizing. Thus, no compressors will be needed between the reactor system and the hydrotreater of the refinery plant. This reduces the overall cost of the plant with a reactor system of the invention.

TABLE-US-00005 TABLE 5 Size of macroscopic structure: Edge size [m]  0.53 Height [m] 2.3 Number of macroscopic structures 9   Total volume of structured catalyst [L] 5888    Structured catalyst height/diagonal length [—]  1.01 Feed gas Product gas T [° C.] 500 1236 P [kg/cm.sup.2 g] 181.97 181.47 CO2 [Nm.sup.3/h] 86 395 N2 [Nm.sup.3/h] 21 21 CH4 [Nm.sup.3/h] 2116 96 H2 [Nm.sup.3/h] 278 6648 CO [Nm.sup.3/h] 0 1711 H2O [Nm.sup.3/h] 6425 4096 Total flow [Nm.sup.3/h] 8926 12967 ΔT.sub.app, SMR [° C.] 10 Power [kW] 9899    Heat flux [kW/m.sup.2] 2.2 Space velocity [Nm.sup.3/m.sup.3/h] 1516   

Example 6

[0195] Example 6 relates to a reactor system comprising a structured catalyst in the form of a structured catalyst having in total 78540 channels with a total wall length of one channel in the cross section of 0.00628 m each and a length of 2 m, giving a total surface area of 987 m.sup.2 of catalyst surface. For a reactor system with this structured catalyst, a simulation with varying gas flow through the structured catalyst was made where the gas composition in all calculations was 8.8% H.sub.2, 56.8% H.sub.2O, 0.2% N.sub.2, 0.1% CO, 2.3% CO.sub.2, and 31.8% CH.sub.4. In each simulation a kinetic model for steam reforming and water gas shift was used and a variation in the surface flux (Q) of energy from the electrically heated structured catalyst was made to adjust the exit temperature of the product gas from the reactor system housing the structured catalyst to 920° C. The kinetic model used was similar to the approach used by Xu and Froment, (J. Xu and G. F. Froment, Methane steam reforming, methanation and water-gas shift: I. intrinsic kinetics. American Institution of Chemical Engineers Journal, 35:88-96, 1989.). FIG. 14 shows the approach to equilibrium along the reactor system length at varying total flows. The Figure shows that at low feed flows (10000 Nm.sup.3/h), the approach to the equilibrium at the outlet the reactor system is below 5° C., which translate into a hydrocarbon conversion of 77%, while at the high flows (150000 Nm.sup.3/h) the approach to equilibrium is above 60° C., which correspond to a hydrocarbon conversion of only 64%, and the hydrocarbons therefore are used less efficiently. The close control of the heat flux in the current invention therefore allows for controlling the approach to equilibrium closely along the length of the reactor system. A general trend in all the curves in FIG. 14 is that the approach to equilibrium is continuously decreasing until a pseudo equilibrium is reached, where the heat added and the heat consumed roughly equal each other.

[0196] The approach to equilibrium from this stage is substantially constant or has a slightly increasing development due to the overall increasing temperature of the reactor system.

Example 7 (Comparative Example)

[0197] An SMR with a number of identical tubes is provided. Each tube has an internal diameter of 10 cm and a length of 13 m. The total heat flux to the SMR tubes is adjusted to an average heat flux (based on the surface area of the inner surface of the tubes) of 90,000 kcal/h/m.sup.2 corresponding to ca. 105 kW/m.sup.2. Each tube is loaded with catalyst pellets. The dimensions of the catalyst pellets are adjusted to give a void fraction of 60%. Such a configuration allows for processing around 410 Nm.sup.3/h of process gas per tube in the SMR, when the feed gas has a composition of 8.8% hydrogen, 56.8% water, 0.2% nitrogen, 0.1% carbon monoxide, 2.3% carbon dioxide, and 31.8% methane.

[0198] This gives: [0199] Total internal tube volume (volume limited by the interior surface of the tube and the height of the tube): 0.1021 m.sup.3 [0200] Internal tube volume occupied by catalyst material: 0.0408 m.sup.3 [0201] Total amount of internal tube volume occupied by catalyst material per unit of internal reactor system volume: 0.4 m.sup.3/m.sup.3 [0202] Total amount of energy supplied to the tube interior: 427.4 kW [0203] Amount of energy supplied to the tube interior per unit of tube interior volume: 4186 kW/m.sup.3. [0204] Gas processed per reactor catalyst volume: 4015 Nm.sup.3/m.sup.3/h.

Example 8

[0205] A reactor system according to the invention is provided. A structured catalyst with a geometric surface area of 800 m.sup.2/m.sup.3 is provided. 95% of the area is covered with a ceramic coating with catalytically active material. The ceramic coating has a thickness of 0.1 mm. A power of 9 kW/m.sup.2 of surface area of the structured catalyst is applied. Such a reactor can process ca. 7700 Nm.sup.3/m.sup.3/h relative to the volume of the structured catalyst, when the feed gas has a composition of 8.8% hydrogen, 56.8% water, 0.2% nitrogen, 0.1% carbon monoxide, 2.3% carbon dioxide, and 31.8% methane.

[0206] This gives: [0207] Amount of energy supplied to the structured catalyst per unit of structured catalyst volume: 7200 kW/m.sup.3. [0208] Total amount of internal reactor system volume occupied by catalyst per unit of internal reactor system volume: 0.076 m.sup.3/m.sup.3. [0209] Gas processed per reactor catalyst volume: 101315 Nm.sup.3/m.sup.3/h

[0210] It is seen by comparing with Example 7, that the internal reactor system volume can be made much more compact. In addition, in the reactor system according to the invention, no furnace is needed thus substantially reducing the reactor size.

[0211] Furthermore, the amount of catalytically active material is reduced considerably compared to the state of the art.