WALLS FOR CATALYTIC BEDS OF RADIAL- OR AXIAL-FLOW REACTORS

Abstract

Radial or axial-radial flow catalytic chemical reactor comprising a cylindrical shell and at least one catalytic bed and comprising a plurality of perforated tubes, said tubes having an open end communicating with an inlet of a gaseous flow of reagents in the reactor, said tubes being provided with a plurality of holes on their side surface, said tubes being arranged around the catalytic bed so as to form an outer wall which bounds the catalytic bed and which distributes the reagents inside said bed; each of said tubes being formed by means of longitudinal or helical butt welding of a perforated strip.

Claims

1-14. (canceled)

15. A radial flow or an axial-radial flow catalytic chemical reactor, comprising: a cylindrical shell; at least one catalytic bed; and a plurality of perforated tubes that are arranged around the at least one catalytic bed to form a distributor of reagents into said at least one catalytic bed; wherein each of said plurality of perforated tubes include an open end in communication with an inlet of a gaseous flow of reagents in the catalytic chemical reactor, and a closed end opposite to said inlet end; wherein each of said plurality of perforated tubes includes a butt welded perforated strip or a butt welded perforated metal sheet.

16. The radial flow or axial-radial flow catalytic chemical reactor of claim 15, wherein the butt welded perforated strip or the butt welded perforated metal sheet is automatically butt welded.

17. The radial flow or axial-radial flow catalytic chemical reactor of claim 15, wherein said butt welded perforated strip is helically wound and helically welded.

18. The radial flow or axial-radial flow catalytic chemical reactor of claim 15, wherein said butt weld of each of said plurality of perforated tubes includes a straight longitudinal butt weld.

19. The radial flow or axial-radial flow catalytic chemical reactor of claim 15, wherein each of said plurality of perforated tubes is cylindrical and has a circular cross-section.

20. The radial flow or axial-radial flow catalytic chemical reactor of claim 19, wherein each of said plurality of perforated tubes has a ratio between a wall thickness thereof and a diameter thereof that is less than or equal to 1/10.

21. The radial flow or axial-radial flow catalytic chemical reactor of claim 20, wherein said ratio is less than or equal to 1/20.

22. The radial flow or axial-radial flow catalytic chemical reactor of claim 15, wherein each of said plurality of perforated tubes has a flattened cross-section, an oval cross-section, or a substantially elliptical cross-section.

23. The radial flow or axial-radial flow catalytic chemical reactor of claim 22, wherein each of said plurality of perforated tubes has a ratio between a wall thickness thereof and a perimeter of the flattened cross-section, the oval cross-section, or the substantially elliptical cross-section that is less than or equal to 1/30.

24. The radial flow or axial-radial flow catalytic chemical reactor of claim 23, wherein said ratio is less than or equal to 1/60.

25. The radial flow or axial-radial flow catalytic chemical reactor of claim 15, wherein said plurality of perforated tubes include commercial tubes.

26. The radial flow or axial-radial flow catalytic chemical reactor of claim 25, wherein said commercial tubes include drainage tubes.

27. The radial flow or axial-radial flow catalytic chemical reactor of claim 15, wherein said plurality of perforated tubes extend along a longitudinal axis of said at least one catalytic bed and are in a ring arrangement to form a wall around said at least one catalytic bed.

28. The radial flow or axial-radial flow catalytic chemical reactor of claim 15, wherein each of said plurality of perforated tubes is perforated in a uniform manner over an entire side surface thereof.

29. The radial flow or axial-radial flow catalytic chemical reactor of claim 15, wherein each of said plurality of perforated tubes includes holes with a diameter of at least 1 mm.

30. The radial flow or axial-radial flow catalytic chemical reactor of claim 29, wherein said diameter of said holes is not greater than 5 mm.

31. The radial flow or axial-radial flow catalytic chemical reactor of claim 15, further comprising at least one ring that supports said plurality of perforated tubes.

32. The radial flow or axial-radial flow catalytic chemical reactor of claim 31, wherein said at least one ring includes an outer ring of a cover of the at least one catalytic bed.

33. A method for forming a gas-permeable wall in a catalytic bed for a radial flow chemical reactor or an axial-radial flow chemical reactor, the method comprising: providing at least one catalytic bed; and forming the gas-permeable wall around said at least one catalytic bed from a plurality of perforated tubes that are arranged around the catalytic bed so as to form a distributor of reagents into said catalytic bed; wherein said plurality of perforated tubes are made by helical butt welding or straight butt welding of a perforated strip or a metal sheet.

34. The method of claim 33 wherein said butt welding is performed automatically.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0034] FIG. 1 shows in schematic form a longitudinally sectioned view of an axial-radial reactor according to an embodiment of the invention.

[0035] FIG. 2 shows in schematic form a perspective view of the catalytic bed of the reactor according to FIG. 1.

[0036] FIG. 3 shows in schematic form an embodiment of a perforated tube of the catalytic bed according to FIG. 2.

[0037] FIG. 4 shows an embodiment of a perforated tube which is an alternative to that shown in FIG. 3.

[0038] FIGS. 5 and 6 show examples of the cross-section of the tubes.

[0039] FIGS. 7 and 8 show a solution according to the prior art, FIG. 8 being a detail of FIG. 7.

[0040] FIG. 9 shows an axonometric view of a reactor according to an embodiment of the invention.

DETAILED DESCRIPTION

[0041] FIG. 1 shows a catalytic chemical reactor 1, for example a reactor for the synthesis of ammonia from a synthesis gas comprising hydrogen and nitrogen.

[0042] The reactor 1 comprises a substantially cylindrical shell 2 provided at the top end with an inlet opening 3 for reagent gases 20 and at the bottom end with an outlet opening 4 for a gaseous flow 21 comprising the reaction products.

[0043] The reactor 1 contains a catalytic bed 5 with annular cross-section passed through by an axial-radial flow.

[0044] Said catalytic bed 5 is delimited by an outer wall 6 in the vicinity of the shell 2 and an inner wall 7, for the inlet and outlet of the gases into/from the bed 5, respectively.

[0045] Moreover, the catalytic bed 5 is open at the top so as to allow a first portion 20a of the reagent gas flow to pass axially through it.

[0046] The wall 6 is formed by perforated tubes 10 in a ring arrangement, for example along a circumference. Said tubes 10 have an open top end 11 for the entry of a second portion 20b of the gas flow 20 and a closed bottom end 12. The tubes 10 may be advantageously supported and kept in position by at least one ring 13 (FIG. 2). Said ring 13 is preferably arranged at the top end of the tubes. Further means for supporting the tubes, in some embodiments, consist of a series of supports or guides welded to the walls of the reactor 1.

[0047] The tubes 10 comprise a plurality of holes 14 arranged uniformly along their side surface, in a respective hole arrangement, so as to supply the second gaseous portion 20b to the catalytic bed 5, with an essentially radial flow.

[0048] Said holes 14 have dimensions such as to allow the free passage of the reagent gas, and not of the catalyst of the catalytic bed 5, through them. Preferably said holes are substantially circular and have a diameter of 3 mm.

[0049] Each tube 10 is made from a perforated strip with helical or longitudinal welding.

[0050] FIG. 3 shows a tube 10 made by helical winding of a strip 15 and subsequent helical welding 16 of the edges of the strip. The process is also referred to as spiral welding.

[0051] FIG. 4 shows, instead, an embodiment of the tube 10 with a longitudinal welding 17 (simple longitudinal welding).

[0052] It should be noted that both the helical weld 16 and the longitudinal weld 17 are butt welds, i.e. without edges overlapping. FIG. 4 in particular shows that the longitudinal weld 17 is performed without overlapping the edges 18 and 19 of the perforated strip 15. Moreover, as can be seen in the figure, the holes 14 are distributed over the entire side surface of the tube 10.

[0053] FIGS. 5 and 6 show two examples of cross-sectional views of a tube 10, according to preferred embodiments, with a circular cross-section (FIG. 5) and elliptical cross-section (FIG. 6), respectively. The cross-section of the tube is symmetrical relative to two axes X, Y which are perpendicular to each other.

[0054] Preferably, said tubes 10 are commercial tubes, which are serially produced.

[0055] FIG. 9 shows a preferred embodiment comprising a top cover 22 for the catalytic bed, which supports the tubes 10 and comprises openings 23 to allow a partially axial flow (flow 20a in FIG. 1). The outer ring 24 of said cover 22 operates substantially as a supporting and retaining ring for the tubes 10.

[0056] The wall 6, which is substantially formed by the tubes 10 described above, has the function of both favouring a uniform distribution of the gaseous flow of reagents 20 inside the catalytic bed 5 and of containing and mechanically supporting the catalytic bed 5.

[0057] The inner wall 7 for example is a perforated central tube with a closing cover 9 and defines a collecting chamber 8 for the reaction products. The arrows shown in FIG. 1 indicate the paths followed by the gases inside the reactor and in particular through the catalytic bed 5.

[0058] During operation, the reagent gases 20 enter the catalytic bed partly (flow 20a) with an axial flow through the open top part of the bed, and partly (flow 20b) with a radial flow through the perforated tubes 10. The reaction products are collected inside the chamber 8, forming the output flow 21.