Reactor for producing synthesis gas

Abstract

The present invention relates to a reactor for producing synthesis gas which has a fluid-tight connection to a heat exchanger, and to a process for producing synthesis gas, preferably under high pressure, by using the reactor. The reactor comprises a mixer, a mixing space, a reactor space, separate inlets for at least two fluid reactants and an outlet for at least one fluid product, and a reactor shell surrounding these, and wherein the mixer comprises a mixer base, at least one mixer disk with channels for a first fluid, at least one mixer disk with channels for a second fluid, a mixer closure, and a mixer lid.

Claims

1. A reactor for the preparation of synthesis gas, wherein the reactor comprises a mixer, a mixing space, a reactor space, separate inlets for at least two fluid reactants and an outlet for at least one fluid product, and a reactor shell surrounding these, and wherein the mixer comprises a mixer base, at least one mixer disk with channels for a first fluid, at least one mixer disk with channels for a second fluid, a mixer closure, and a mixer lid and the reactor comprises an outer fluid-tight inlet for at least one reactant between reactor shell and mixer inside the reactor, within which there is disposed at least one fluid-tight inlet for a further reactant, and a countercurrent construction with regard to a flow of the reactants in the inlet between the mixing space and the outlet.

2. The reactor of claim 1, wherein the separate inlets are a concentric double tube.

3. The reactor of claim 1, wherein the mixer has a fluid-tight connection to the separate inlets.

4. The reactor of claim 1, wherein the reactor further comprises at least one catalyst-functionalized monolithic body.

5. The reactor of claim 1, wherein the reactor further comprises at least one heat shield of at least one monolithic body.

6. The reactor of claim 1, wherein the reactor further comprises at least one catalyst-functionalized monolithic body and/or at least one heat shield of at least one monolithic body and wherein the at least one catalyst-functionalized monolithic body and/or the heat shield of at least one monolithic body are each arranged as a ply/layer around the separate inlets within the reactor shell.

7. The reactor of claim 1, wherein the reactor is connected in a fluid-tight manner to a heat exchanger.

8. The reactor of claim 7, wherein the heat exchanger comprises at least two inlets for a fluid cooling medium and at least one inlet and one outlet for the fluid product from the reactor.

9. The reactor of claim 7, wherein the heat exchanger comprises at least two chambers of different size.

10. A process for the production of synthesis gas, wherein the method comprises making the synthesis gas by using the reactor of claim 1.

11. The process of claim 10, wherein synthesis gas is produced under high pressure.

12. The process of claim 10, wherein a first fluid reactant is guided into a mixing chamber through openings in a first mixer disk via channels for the first fluid in a second mixer disk, and a second fluid reactant, after an internal reversal of flow in the mixer lid, is guided into the mixing space through openings in the second mixer disk via channels for a second medium in the first mixer disk.

13. The process of claim 10, wherein reactants are guided into the mixer in a separate flow regime in two concentric inlets, and then guided as a mixture in countercurrent through a first heat shield to a reaction space, and a product formed therein is likewise guided in countercurrent to a feeding of the reactants to discharge the product.

14. The process of claim 13, wherein the product thus formed is guided into a heat exchanger.

15. The process of claim 14, wherein in the heat exchanger the product is cooled in crosscurrent with a fluid medium.

16. The process of claim 10, wherein in an inlet to the reactor a mixture of fuel and water vapor is introduced as a first reactant and, in another separate inlet air is introduced as a second fluid reactant.

17. The process of claim 16, wherein the mixture of fuel and water vapor is introduced in an inner inlet and air is introduced in an outer inlet.

18. The process of claim 16, wherein the air has been heated beforehand as cooling medium in a heat exchanger.

19. The process of claim 16, wherein a cooling surface of a heat exchanger for formed product is adapted to an amount of product by opening up at least one further inlet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the accompanying drawings,

(2) FIG. 1 shows a cross-section of an embodiment of a reactor according to the invention;

(3) FIG. 2 shows a mixer of a reactor of the invention;

(4) FIG. 3 shows a heat-exchanger for a reactor of the invention; and

(5) FIG. 4 shows schematically a reactor of the invention with heat exchanger.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(6) In one embodiment, the reactor of the invention and the heat exchanger of the invention are used in the process of the invention for production of synthesis gas as follows:

(7) The reactor (1-01) is shown in FIG. 1: what is shown is the reactor housing in cross section.

(8) The screws (1-11) are released for disassembly and the reactor shell and reactor are opened. What is clearly apparent is the easy accessibility of the individual elements of the reactor. The stable design allows operation under high pressure, preferably at about 30 bar.

(9) For the production of synthesis gas, air is preferably fed into the outer inlet (1-02) of the two concentric inlets, preferably in the form of a double tube.

(10) The second reactant, preferably a fuel, preferably comprising CH4 mixed with water vapor, is fed into the inner inlet (1-03). The water vapor is preferably generated externally, but may also be in the form of an aerosol in the gas or be atomized in the mixer. The two concentric inlets (1-05) convey the two reactants in axial direction to the mixer (1-06). The mixer is shown in FIG. 2. The mixer consists of a mixer base which is preferably in the form of a disk, such that the inner inlet (2-03=1-03) is conducted through the opening of the disk. The mixer base (2-02) closes the outer inlet (2-01=1-02) and has multiple holes for the flow of the reactant in the outer inlet, preferably air. The mixer base is followed by a mixer disk (2-04) with the corresponding channels for the reactant in the inner inlet, preferably gas and water vapor, to exit the mixer. This disk has holes through which the reactant in the outer inlet, preferably the air, can flow.

(11) This is followed by a further disk (2-05) provided with the channels that allow the reactant in the outer inlet, preferably air, to exit the mixer. The disks (2-04) and (2-05) that allow the reactants to exit the mixer can be inserted as often as desired, as shown in FIG. 2. The last disk that allows the reactants to exit the mixer in the outer inlet follows the mixer closure (2-06). This has holes for the passage of the reactant in the inner inlet, preferably gas and water vapor.

(12) As described above, the elements mixer base (2-02) and disks (2-04 and 2-05) that allow the reactants to exit the mixer, in any number, and the mixer closure (2-06) are connected to one another in a fluid-tight manner, such that the reactants can flow through the corresponding holes. These disks are preferably welded to one another and placed onto and secured, preferably welded, to the inner inlet, preferably the inner tube in the double tube.

(13) As its last element, the mixer has the mixer lid (2-7) which is responsible for deflection of flow of the reactant in the inner inlet.

(14) The mixer exits for the reactants are offset, such that good mixing in the mixer space (1-07) is assured.

(15) The mixer space preferably has an optional partial filling with a ceramic foam or powder.

(16) Outside the inlet, the mixture of the reactants is guided through the heat shield (1-08) in countercurrent to the reaction space (1-09).

(17) After the reaction, the product, preferably reformate, is further guided in countercurrent with respect to the inlet through a further heat shield (1-10) for discharge (1-04).

(18) In one embodiment of the invention, the product is guided into a heat exchanger. An alternative for the heat exchanger is shown in FIG. 3. The product is guided into the heat exchanger via the inlet (3-01). Cooling medium, preferably air, is guided via the inlets 1 and/or 2 (3-02 and/or 3-03), into the heat exchanger. The heated cooling medium is led off via the outlets 1 and 2 (3-04 and/or 3-05), while the cooled product, preferably reformate, is passed on via outlet (3-06).

(19) A preferred construction of the reactor of the invention with heat exchanger of the invention is shown in schematic form in FIG. 4. Synergistic effects can be achieved in that the heated cooling medium (4-11), preferably air, is guided as reactant into the reactor, preferably the outer inlet.

EXAMPLES

(20) For the experiments, a reactor with a first heat shield, a reaction space with 2 monoliths having identical catalysts (commercial) in series, a second heat shield was used.

(21) Monoliths for the heat shields and in the reaction space made of cordierite.

Experimental Conditions

(22) TABLE-US-00001 Experiment 1 2 3 4 x.sub.i [%] 17.24; 11.50; 17.24; 11.50; 16.67; 11.11; 17.24; 11.50; CH4, CO2, 10.77; 43.25; 10.77; 43.25; 11.11; 44.44; 10.77; 43.25; O2, N2, 17.24 17.24 16.67 17.24 H2O v [m/s] at 0.52 0.42 0.43 0.52 0 C. and 1.013 bar p [bar] 30 20 20 1 T.sub.in [ C.] about 340 about 340 about 340 about 320 T.sub.max [ C.] 834 832 865 800 X.sub.CH4 [%] 79 79 83 88 S.sub.H2 [%] 83 79 81 92 S.sub.CO [%] 81 72 77 81 Xi: proportions of the reactants in the mixer space in % v: flow rate p: pressure in inlets or reactor Tin: temperature of the reactants in inlet Tmax: maximum temperature in the reactor/reactor space X(CH4): CH4 conversion S(H2): selectivity for hydrogen S(CO): selectivity for carbon monoxide

LEGEND

(23) The figures are merely a schematic representation; the size ratios may vary.

(24) 1-01reactor

(25) 1-02outer inlet for fluid reactant, preferably air

(26) 1-03inner inlet for fluid reactant, preferably gas+steam

(27) 1-04outlet for product, preferably synthesis gas (reformate)

(28) 1-05concentric inlets, preferably double tube

(29) 1-06mixer

(30) 1-07mixer space, preferably filling with ceramic foam

(31) 1-08heat shield (monolith)

(32) 1-09reaction space, functionalized monolithic (catalyst)

(33) 1-10heat shield (monolith)

(34) 1-11screws for opening and closing the reactor and the reactor shell

(35) 2-01outer inlet, preferably outer tube

(36) 2-02mixer base with passage for reactant in outer inlet, preferably air

(37) 2-03inner inlet, preferably inner tube

(38) 2-04disk allowing reactant in the inner inlet, preferably gas+steam, to exit mixer

(39) 2-05disk allowing reactant in the outer inlet, preferably air, to exit mixer

(40) 2-06mixer closure with passage of reactant in the inner outlet, preferably gas+steam

(41) 2-07mixer lid with deflection of flow for reactant in the inner inlet, preferably gas+steam

(42) 3-01inlet for product from reactor, preferably synthesis gas (reformate)

(43) 3-02inlet 1 for cooling medium, preferably air

(44) 3-03inlet 2 for cooling medium, preferably air

(45) 3-04outlet 1 for heated cooling medium, preferably air

(46) 3-05outlet 2 for heated cooling medium, preferably air

(47) 3-06outlet for cooled product, preferably synthesis gas (reformate)

(48) 4-01reactor=1-01

(49) 4-02inner and outer inlet, preferably in the form of a double tube

(50) 4-03reactant in inner inlet, preferably gas+steam

(51) 4-04mixer=1-06

(52) 4-05heat shield=1-08

(53) 4-06reaction space, functionalized monolith (catalyst)=1-09

(54) 4-07heat shield=1-10

(55) 4-08product, preferably synthesis gas (reformate)=1-04

(56) 4-09heat exchanger

(57) 4-10cooling medium, preferably air,=3-03 and/or 3-04

(58) 4-11heated cooling medium, preferably air, 3-04 and/or 3-05 and 1-02

(59) 4-12cooled product, preferably synthesis gas (reformate)

(60) 4-13valves