US20020048541A1 - Reactor for performing a strongly heat-conditioned catalytic reaction - Google Patents
Reactor for performing a strongly heat-conditioned catalytic reaction Download PDFInfo
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- US20020048541A1 US20020048541A1 US09/931,177 US93117701A US2002048541A1 US 20020048541 A1 US20020048541 A1 US 20020048541A1 US 93117701 A US93117701 A US 93117701A US 2002048541 A1 US2002048541 A1 US 2002048541A1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J19/24—Stationary reactors without moving elements inside
- B01J19/248—Reactors comprising multiple separated flow channels
- B01J19/249—Plate-type reactors
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B17/00—Sulfur; Compounds thereof
- C01B17/02—Preparation of sulfur; Purification
- C01B17/04—Preparation of sulfur; Purification from gaseous sulfur compounds including gaseous sulfides
- C01B17/0404—Preparation of sulfur; Purification from gaseous sulfur compounds including gaseous sulfides by processes comprising a dry catalytic conversion of hydrogen sulfide-containing gases, e.g. the Claus process
- C01B17/0413—Preparation of sulfur; Purification from gaseous sulfur compounds including gaseous sulfides by processes comprising a dry catalytic conversion of hydrogen sulfide-containing gases, e.g. the Claus process characterised by the combustion step
- C01B17/0417—Combustion reactors
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- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B17/00—Sulfur; Compounds thereof
- C01B17/02—Preparation of sulfur; Purification
- C01B17/04—Preparation of sulfur; Purification from gaseous sulfur compounds including gaseous sulfides
- C01B17/0404—Preparation of sulfur; Purification from gaseous sulfur compounds including gaseous sulfides by processes comprising a dry catalytic conversion of hydrogen sulfide-containing gases, e.g. the Claus process
- C01B17/046—Preparation of sulfur; Purification from gaseous sulfur compounds including gaseous sulfides by processes comprising a dry catalytic conversion of hydrogen sulfide-containing gases, e.g. the Claus process without intermediate formation of sulfur dioxide
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- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B17/00—Sulfur; Compounds thereof
- C01B17/69—Sulfur trioxide; Sulfuric acid
- C01B17/74—Preparation
- C01B17/76—Preparation by contact processes
- C01B17/80—Apparatus
- C01B17/803—Converters
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- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
- C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
- C01B3/06—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of inorganic compounds containing electro-positively bound hydrogen, e.g. water, acids, bases, ammonia, with inorganic reducing agents
- C01B3/12—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of inorganic compounds containing electro-positively bound hydrogen, e.g. water, acids, bases, ammonia, with inorganic reducing agents by reaction of water vapour with carbon monoxide
- C01B3/16—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of inorganic compounds containing electro-positively bound hydrogen, e.g. water, acids, bases, ammonia, with inorganic reducing agents by reaction of water vapour with carbon monoxide using catalysts
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01C—AMMONIA; CYANOGEN; COMPOUNDS THEREOF
- C01C1/00—Ammonia; Compounds thereof
- C01C1/02—Preparation, purification or separation of ammonia
- C01C1/04—Preparation of ammonia by synthesis in the gas phase
- C01C1/0405—Preparation of ammonia by synthesis in the gas phase from N2 and H2 in presence of a catalyst
- C01C1/0417—Preparation of ammonia by synthesis in the gas phase from N2 and H2 in presence of a catalyst characterised by the synthesis reactor, e.g. arrangement of catalyst beds and heat exchangers in the reactor
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
- C07C5/02—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by hydrogenation
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
- C07C5/02—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by hydrogenation
- C07C5/03—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by hydrogenation of non-aromatic carbon-to-carbon double bonds
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
- C07C5/02—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by hydrogenation
- C07C5/08—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by hydrogenation of carbon-to-carbon triple bonds
- C07C5/09—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by hydrogenation of carbon-to-carbon triple bonds to carbon-to-carbon double bonds
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C9/00—Aliphatic saturated hydrocarbons
- C07C9/02—Aliphatic saturated hydrocarbons with one to four carbon atoms
- C07C9/04—Methane
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07D—HETEROCYCLIC COMPOUNDS
- C07D301/00—Preparation of oxiranes
- C07D301/02—Synthesis of the oxirane ring
- C07D301/03—Synthesis of the oxirane ring by oxidation of unsaturated compounds, or of mixtures of unsaturated and saturated compounds
- C07D301/04—Synthesis of the oxirane ring by oxidation of unsaturated compounds, or of mixtures of unsaturated and saturated compounds with air or molecular oxygen
- C07D301/08—Synthesis of the oxirane ring by oxidation of unsaturated compounds, or of mixtures of unsaturated and saturated compounds with air or molecular oxygen in the gaseous phase
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2/00—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon
- C10G2/30—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen
- C10G2/32—Production of liquid hydrocarbon mixtures of undefined composition from oxides of carbon from carbon monoxide with hydrogen with the use of catalysts
- C10G2/34—Apparatus, reactors
- C10G2/341—Apparatus, reactors with stationary catalyst bed
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2451—Geometry of the reactor
- B01J2219/2453—Plates arranged in parallel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2451—Geometry of the reactor
- B01J2219/2456—Geometry of the plates
- B01J2219/2458—Flat plates, i.e. plates which are not corrugated or otherwise structured, e.g. plates with cylindrical shape
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2461—Heat exchange aspects
- B01J2219/2462—Heat exchange aspects the reactants being in indirect heat exchange with a non reacting heat exchange medium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2474—Mixing means, e.g. fins or baffles attached to the plates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2476—Construction materials
- B01J2219/2477—Construction materials of the catalysts
- B01J2219/2479—Catalysts coated on the surface of plates or inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2491—Other constructional details
- B01J2219/2497—Size aspects, i.e. concrete sizes are being mentioned in the classified document
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2491—Other constructional details
- B01J2219/2498—Additional structures inserted in the channels, e.g. plates, catalyst holding meshes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P20/00—Technologies relating to chemical industry
- Y02P20/50—Improvements relating to the production of bulk chemicals
- Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts
Definitions
- the invention relates to a reactor for performing heat-conditioned catalytic reaction within a process fluid, equipped with plates that are arranged parallel to one another at a distance to form flat channels with lateral boundary areas that face one another, whereby a portion of the channels contain a solid catalyst and carry the process fluid, and another portion of the channels guide a heat transfer medium in indirect heat contact with the process fluid.
- a tube reactor with catalyst particles in the tubes is known from the journal Hydrocarbon Processing, March 1997, page 134.
- the tubes are cooled on the jacket side of the reactor with boiling water or other suitable heat transfer media.
- the division of the reaction chamber and the catalyst particles in several tubes guarantees that in the case of a malfunction, a self-accelerating reaction, caused by local superheating, is limited to a reaction tube and does not extend to the entire reactor.
- the reactor design has proven its value, but it also exhibits several drawbacks.
- the reactor jacket must often be designed for high coolant pressure. As a result, the jacket is very thick and thus costly, and the reactor is difficult to transport.
- a plate heat exchanger with a catalyst solid bed is known from DE 198 04 806 A1. It contains cooled separating walls in the bed.
- the reactor jacket must be designed only for the pressure of the reaction gas; the reactor requires no tube bottoms. It is thus lighter overall than a tube reactor and therefore can also be made from high-grade steel at lower cost.
- a prior art reactor closely related to the present invention is disclosed in U.S. Pat. No. 3,528,783. Rectangular channels formed with bent sheets direct, on the one hand, a reaction medium and, on the other hand, a heat transfer medium.
- the channels through which the reaction medium flows contain solid catalyst material. These channels are sandwich-like positioned between channels through which the heat transfer medium flows.
- An object of the invention is therefore to avoid the above-mentioned drawbacks.
- a reactor comprising plates that are arranged parallel to one another at a distance and form flat channels with lateral boundary areas that face one another.
- a portion of the channels contain a solid catalyst and carry a process fluid, and another portion of the channels guide a heat transfer medium in indirect heat contact with the process fluid.
- the plates are flat or are provided with grooves or ribs and are coated at least partially with catalyst on the surface that faces the process fluid.
- a characteristic feature of the invention is that the plates are flat, or are provided with grooves or ribs, and are coated at least partially with the catalyst on the surface that faces the process fluid.
- a significant temperature profile cannot form crosswise to the direction of flow, since the heat input or output always takes the shortest path, namely through the plates and the layer that is applied to the plates.
- a uniform flow through all of the channels is achieved even more readily than in catalytic-bed channels (or tubes).
- heat transfer zones can be formed in parts of the reactor which do not also provide catalytic reaction.
- the lateral boundary areas can be designed as jacket pieces, which form a pressure-resistant cuboid block with channels formed by the plates and collectors for the process fluid and for the heat transfer medium.
- An advantage of this embodiment is that the reactor can be operated, both on the process fluid side and on the heat transfer medium side, at operating pressures of more than 25 bar.
- the channels that carry the process fluid can contain corrugated and pleated sheets (fins) that form passages for the process fluid.
- the heat transfer between the process fluid and the heat transfer medium is improved by the fins.
- the fins can be perforated and thus form flow connections between the passages.
- the fins can be coated on both sides at least partially with catalyst material. With the thickness of the coating being the same, in this way a more effective catalyst surface is installed per reactor volume.
- the width of the passages for process fluid formed by the coated fins is preferably about 0.5-5 mm.
- the catalyst layer can contain a support medium.
- the catalyst layer can have a layer thickness of, for example, 1 to 500 ⁇ m, preferably 10 to 100 ⁇ m.
- the distance between plates (without catalyst coating) is preferably about 2.5-20 mm.
- the reactor according to the invention can be made of aluminum, steel or high-grade steel.
- the reactor according to the invention is used especially advantageously when an endothermic reaction or an exothermic reaction is performed in the reactor. Without limiting the usability of the reactor, the following are examples of processes in which the reactor can be used.
- the reactor according to the invention can advantageously be used in:
- FIG. 1 shows a reactor according to the invention in three-dimensional representation.
- a reactor with a volume of 13 m 3 can be used Length 6 m Width 1.2 m Depth 1.8 m Weight without catalyst 16 t
- the catalyst-coated channels have a pressure drop of about 150 mbar.
- a comparable reactor according to the prior art has a volume that is greater by a factor of 4 to 10.
- the catalyst can comprise a noble metal, e.g., palladdium, and a support material, e.g., aluminum oxide.
- the catalyst layer can be applied as a coating, e.g., a washcoat. See, e.g., Handbook of Heterogeneous Catalysis, Vol. 14, 11 Environmental Catalysis-Mobile Sources, pp. 1572-83.
- the catalyst layer can also be applied by chemical vapor deposition (CVD)as described, e.g., in the Handbook of Heterogeneous Catalysis, Vol. 2, pp. 853-55.
- FIG. 1 illustrates an embodiment of the invention.
- Plates 1 that are arranged parallel to one another at a distance and form channels 2 , for a process fluid, and channels 3 , for a cooling medium, with lateral boundary areas that face one another.
- the boundary areas can be designed as plates 4 (shown as broken lines in the figure) or as webs 5 between plates 1 and/or (not shown in the figure) between fins and plates 1 .
- the plate surfaces inside of the channels that guide the process fluid are coated with catalyst material 6 .
- collectors for the process fluid and the cooling medium which together with the plates form a dimensionally stable and pressure-resistant reactor 7 .
- An acetylene-containing flow 8 is fed to, for example, reactor 7 .
- the acetylene is hydrogenated to ethylene in the presence of catalyst material 6 , and a flow 9 containing ethylene is obtained.
- Process heat that is formed as a result of the catalytic reaction is withdrawn from the plates by the flow of liquid butane 10 , which is fed to channels 3 . As heat is taken up, the butane is evaporated and withdrawn as a gaseous flow 11 .
Abstract
The invention relates to a reactor for performing a strongly heat-conditioned catalytic reaction in a process fluid, equipped with plates that are arranged parallel to one another at a distance and that form flat channels with lateral boundary areas that face one another, whereby a portion of the channels contains a solid catalyst and carries the process fluid, and another portion of the channels guides a heat transfer medium in indirect heat contact with the process fluid.
According to the invention, plates (1) are flat or are provided with grooves or ribs, and plates (1) are coated at least partially with catalyst (6) on the surface that faces the process fluid.
Description
- The invention relates to a reactor for performing heat-conditioned catalytic reaction within a process fluid, equipped with plates that are arranged parallel to one another at a distance to form flat channels with lateral boundary areas that face one another, whereby a portion of the channels contain a solid catalyst and carry the process fluid, and another portion of the channels guide a heat transfer medium in indirect heat contact with the process fluid.
- Catalytic processes are often connected with high energy conversions. In most cases, a specific temperature range must be maintained to achieve a high conversion and high yield of desirable products (selectivity,) and to avoid damaging the catalyst that is used. Adiabatic reactors with intermediate cooling result in a considerable number of components or in a reactor of expensive design. Solid-bed reactors with cooling and heating devices in the bed are also known. In most cases, these are tubular reactors with a solid bed and with heat-transfer-medium-guiding tubes in the solid bed, as they are described in all standard works on reaction technology, for example in Ullmann's Encyclopedia of Industrial Chemistry, VCH 1992, Vol. 4B. A reactor with coiled coolant tubes in a solid bed is disclosed in M. Lehmbeck's “Linde Isothermal Reactor for Methanol Synthesis” 41 (1986),
pages 5 to 8. - A tube reactor with catalyst particles in the tubes is known from the journal Hydrocarbon Processing, March 1997, page 134. The tubes are cooled on the jacket side of the reactor with boiling water or other suitable heat transfer media. The division of the reaction chamber and the catalyst particles in several tubes guarantees that in the case of a malfunction, a self-accelerating reaction, caused by local superheating, is limited to a reaction tube and does not extend to the entire reactor. The reactor design has proven its value, but it also exhibits several drawbacks.
- In practice, the reactor jacket must often be designed for high coolant pressure. As a result, the jacket is very thick and thus costly, and the reactor is difficult to transport.
- In the case of a large diameter, the tube bottoms are also very thick and jeopardized by thermal stress.
- The many reaction tubes can be filled only at great expense. In particular, attention must be paid to uniform filling with equal pressure loss in the various tubes, so that a sparingly loaded reaction tube because of a large pressure drop does not become overheated.
- Because of the high weight, in most cases C-steel is used, although rust is thus unavoidable. For many reactions, however, rust acts as a catalyst poison.
- A plate heat exchanger with a catalyst solid bed is known from DE 198 04 806 A1. It contains cooled separating walls in the bed. The reactor jacket must be designed only for the pressure of the reaction gas; the reactor requires no tube bottoms. It is thus lighter overall than a tube reactor and therefore can also be made from high-grade steel at lower cost.
- A prior art reactor closely related to the present invention is disclosed in U.S. Pat. No. 3,528,783. Rectangular channels formed with bent sheets direct, on the one hand, a reaction medium and, on the other hand, a heat transfer medium. The channels through which the reaction medium flows contain solid catalyst material. These channels are sandwich-like positioned between channels through which the heat transfer medium flows.
- The drawback to this multi-layer catalytic reactor—as also to other catalytic-bed reactors—is that during operation a temperature profile forms in the channels that contain the catalyst material crosswise to the direction of flow of the reaction medium. As a result, only an average temperature can be set. An optimal conversion and an optimal selectivity can therefore not be achieved in principle. In addition, a local superheating of the catalyst material and an overflowing of the reaction in a way that is undesirable or even hazardous cannot be ruled out. In addition, the above-mentioned multi-layer reactor has the drawback that it requires a pressure-resistant outer container.
- An object of the invention is therefore to avoid the above-mentioned drawbacks.
- Upon further study of the specification and appended claims, further objects and advantages of this invention will become apparent to those skilled in the art.
- These objects are achieved according to the invention by a reactor comprising plates that are arranged parallel to one another at a distance and form flat channels with lateral boundary areas that face one another. A portion of the channels contain a solid catalyst and carry a process fluid, and another portion of the channels guide a heat transfer medium in indirect heat contact with the process fluid. The plates are flat or are provided with grooves or ribs and are coated at least partially with catalyst on the surface that faces the process fluid.
- A characteristic feature of the invention is that the plates are flat, or are provided with grooves or ribs, and are coated at least partially with the catalyst on the surface that faces the process fluid. With the reactor according to the invention, a significant temperature profile cannot form crosswise to the direction of flow, since the heat input or output always takes the shortest path, namely through the plates and the layer that is applied to the plates. In addition, a uniform flow through all of the channels is achieved even more readily than in catalytic-bed channels (or tubes). Also, in the case of only partial coating with catalyst, heat transfer zones can be formed in parts of the reactor which do not also provide catalytic reaction.
- In an embodiment of the reactor according to the invention, advantageously the lateral boundary areas can be designed as jacket pieces, which form a pressure-resistant cuboid block with channels formed by the plates and collectors for the process fluid and for the heat transfer medium. An advantage of this embodiment is that the reactor can be operated, both on the process fluid side and on the heat transfer medium side, at operating pressures of more than 25 bar.
- The channels that carry the process fluid can contain corrugated and pleated sheets (fins) that form passages for the process fluid. The heat transfer between the process fluid and the heat transfer medium is improved by the fins.
- The fins can be perforated and thus form flow connections between the passages.
- The fins can be coated on both sides at least partially with catalyst material. With the thickness of the coating being the same, in this way a more effective catalyst surface is installed per reactor volume. The width of the passages for process fluid formed by the coated fins is preferably about 0.5-5 mm.
- The catalyst layer can contain a support medium.
- The catalyst layer can have a layer thickness of, for example, 1 to 500 μm, preferably 10 to 100 μm.
- The distance between plates (without catalyst coating) is preferably about 2.5-20 mm.
- The reactor according to the invention can be made of aluminum, steel or high-grade steel.
- The reactor according to the invention is used especially advantageously when an endothermic reaction or an exothermic reaction is performed in the reactor. Without limiting the usability of the reactor, the following are examples of processes in which the reactor can be used.
- The reactor according to the invention can advantageously be used in:
- Synthesis of methanol,
- Synthesis of higher alcohols,
- Hydrogenation of hydrocarbons,
- Selective hydrogenation of C2H2 to C2H4,
- Non-selective hydrogenation of C2H4 to C2H6,
- Methanation or synthesis of methane,
- Carbon monoxide conversion,
- Fischer-Tropsch synthesis,
- Epoxidation,
- Synthesis of ethylene oxide,
- Claus reaction,
- Direct oxidation of H2S to sulfur,
- Oxidation of SO2 to SO3
- or in NH3 synthesis.
- Various other features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawing. FIG. 1 shows a reactor according to the invention in three-dimensional representation.
- In the foregoing and in the following examples, all temperatures are set forth uncorrected in degrees Celsius; and, unless otherwise indicated, all parts and percentages are by weight.
- The entire disclosure of all applications, patents and publications, cited above and below, and of corresponding German Application No. 100 40 209.7, filed Aug. 17, 2000, is hereby incorporated by reference.
- In a selective hydrogenation of acetylene to ethylene with a reactor according to the invention, with fins, operated under the following parameters
Pressure 31 bar Temperature 70-80° C. Throughput 170,000 kg/h - and with use of liquid butane for cooling, a reactor with a volume of 13 m3 can be used
Length 6 m Width 1.2 m Depth 1.8 m Weight without catalyst 16 t - The catalyst-coated channels have a pressure drop of about 150 mbar. A comparable reactor according to the prior art has a volume that is greater by a factor of 4 to 10.
- The catalyst can comprise a noble metal, e.g., palladdium, and a support material, e.g., aluminum oxide. The catalyst layer can be applied as a coating, e.g., a washcoat. See, e.g., Handbook of Heterogeneous Catalysis, Vol. 14, 11 Environmental Catalysis-Mobile Sources, pp. 1572-83. The catalyst layer can also be applied by chemical vapor deposition (CVD)as described, e.g., in the Handbook of Heterogeneous Catalysis, Vol. 2, pp. 853-55.
- The invention is explained in more detail in conjunction with the following description of FIG. 1 which illustrates an embodiment of the invention.
- The principle design of such a reactor is diagrammatically represented in the figure. The function of the reactor is described based on the example of the selective hydrogenation of acetylene to ethylene.
-
Plates 1 that are arranged parallel to one another at a distance andform channels 2, for a process fluid, and channels 3, for a cooling medium, with lateral boundary areas that face one another. The boundary areas can be designed as plates 4 (shown as broken lines in the figure) or aswebs 5 betweenplates 1 and/or (not shown in the figure) between fins andplates 1. The plate surfaces inside of the channels that guide the process fluid are coated with catalyst material 6. Not shown in the figure are collectors for the process fluid and the cooling medium, which together with the plates form a dimensionally stable and pressure-resistant reactor 7. - An acetylene-containing
flow 8 is fed to, for example,reactor 7. Inchannels 2, the acetylene is hydrogenated to ethylene in the presence of catalyst material 6, and aflow 9 containing ethylene is obtained. Process heat that is formed as a result of the catalytic reaction is withdrawn from the plates by the flow ofliquid butane 10, which is fed to channels 3. As heat is taken up, the butane is evaporated and withdrawn as agaseous flow 11. - By removing heat right at the point of origin, secondary reactions such as formation of ethane or oligomers (e.g., anthracene oil, green oil) are largely avoided. Thus, by the more reliable operation of the reactor according to the invention, a high ethylene yield is achieved.
- The preceding examples can be repeated with similar success by substituting the generically or specifically described reactants and/or operating conditions of this invention for those used in the preceding examples.
- From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
Claims (24)
1. A reactor for performing a heat-conditioned catalytic reaction in a process fluid, said reactor comprising: plates that are arranged parallel to one another at a distance and that form flat channels with lateral boundary areas that face one another, wherein a portion of said channels contain a solid catalyst and carry a process fluid, and another portion of said channels carry a heat transfer medium in indirect heat contact with the process fluid, wherein said plates are flat or are provided with grooves or ribs and are coated at least partially with a catalyst on the surface that faces the process fluid.
2. A reactor according to claim 1 , wherein said lateral boundary areas are jacket pieces, which form a pressure-resistant cuboid block with said channels, plates, and with collectors for the process fluid and for the heat transfer medium.
3. A reactor according to claim 1 , wherein the channels which carry the process fluid contain corrugated or pleated sheets which form passages for the flow of process fluid.
4. A reactor according to claim 3 , wherein said sheets are perforated and thereby provide flow connections between said passages.
5. A reactor according to claim 3 , wherein said sheets are coated at least partially on both sides with catalyst material.
6. A reactor according to claim 1 , wherein said catalyst layer contains a support medium.
7. A reactor according to claim 1 , wherein said catalyst layer has a thickness of 1-500 μm.
8. A reactor according to claim 1 , wherein said catalyst layer has a thickness of 10-100 μm.
9. A reactor according to claim 1 , wherein said reactor is made of aluminum.
10. A reactor according to claim 1 , wherein said reactor is made of steel or high-grade steel.
11. In a method of performing an endothermic or exothermic reaction within a reaction, the improvement wherein said reactor is according to claim 1 .
12. A method according to claim 11 , wherein said reaction is synthesis of methanol or synthesis of higher alcohols.
13. A method according to claim 11 , wherein said reaction is hydrogenation of hydrocarbons.
14. A method according to claim 13 , wherein said reaction is selective hydrogenation of C2H2 to C2H4.
15. A method according to claim 13 , wherein said reaction is non-selective hydrogenation of C2H4 to C2H6.
16. A method according to claim 11 , wherein said reaction is methanation or in the synthesis of methane.
17. A method according to claim 11 , wherein said reaction is conversion of carbon monoxide.
18. A method according to claim 11 , wherein said reaction is Fischer-Tropsch synthesis.
19. A method according to claim 11 , wherein said reaction is epoxidation.
20. A method according to claim 19 , wherein said reaction is synthesis of ethylene oxide.
21. A method according to claim 11 , wherein said reaction is Claus reaction.
22. A method according to claim 11 , wherein said reaction is direct oxidation of H2S to sulfur.
23. A method according to claim 11 , wherein said reaction is oxidation of SO2 to SO3.
24. A method according to claim 11 , wherein said reaction is synthesis of NH3.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE10040209.7 | 2000-08-17 | ||
DE10040209A DE10040209A1 (en) | 2000-08-17 | 2000-08-17 | Reactor for carrying out a strongly heat-toned catalytic reaction |
Publications (1)
Publication Number | Publication Date |
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US20020048541A1 true US20020048541A1 (en) | 2002-04-25 |
Family
ID=7652739
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US09/931,177 Abandoned US20020048541A1 (en) | 2000-08-17 | 2001-08-17 | Reactor for performing a strongly heat-conditioned catalytic reaction |
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US (1) | US20020048541A1 (en) |
EP (1) | EP1180395B1 (en) |
JP (1) | JP2002126498A (en) |
AT (1) | ATE387957T1 (en) |
DE (2) | DE10040209A1 (en) |
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Also Published As
Publication number | Publication date |
---|---|
EP1180395B1 (en) | 2008-03-05 |
JP2002126498A (en) | 2002-05-08 |
ATE387957T1 (en) | 2008-03-15 |
DE50113680D1 (en) | 2008-04-17 |
DE10040209A1 (en) | 2002-02-28 |
EP1180395A2 (en) | 2002-02-20 |
EP1180395A3 (en) | 2002-12-04 |
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