Abstract:
A reactor (10) includes a reactor block (12) which defines a multiplicity of first channels (15) and defines a multiplicity of second channels (16) that are thermal contact with the first channels (15). The reactor block (12) is produced by a three- dimensional printing process from a powder. Catalytic inserts (22, 24) may then be introduced into the channels.
Abstract:
A reactor (10) defines first and second flow channels (16, 17) with a removable combustion catalyst insert (24) provided in each of those channels (17) in which a combustion reaction is to occur. The combustion catalyst insert comprising a first portion (Q2) including active catalytic material, a second portion (Q1) having a catalytic activity less than 0.2 times the catalytic activity of the first portion (Q2), and a third portion (P) including active catalytic material with an activity at least 0.3 times that of the first portion (Q2). The first portion (Q2), the second portion (Q1), and the third portion (P) are progressively further from the inlet; and they may be integral with each other.
Abstract:
A gas-to-liquids plant (10) for treating natural gas (5) includes a synthesis-gas-producing catalytic reactor (30) to produce a synthesis gas containing hydrogen and carbon monoxide, and a Fischer-Tropsch synthesis reactor (55) for generating hydrocarbons, and producing a tail gas, and also means (52) to generate a hydrogen-rich gas stream (34) from the synthesis gas or from the tail gas. The plant (10) also incorporates a hydrogen- desulphurisation reactor (87, 90) and means (86) to supply both the natural gas and the hydrogen-rich gas stream to the hydrogen-desulphurisation reactor during normal operation. The plant (10) also may comprise a hydrogen production module (92, 95) for use at start-up of the plant. The reactor (30) may comprise a partly-sacrificial catalyst bed.
Abstract:
A steam reforming plant for reforming a hydrocarbon comprises a pre-reforming reactor (28) and a steam reforming reactor (30), and a stream of hydrocarbon is passed through the pre-reforming reactor (28) and then through a duct (72) to the steam reforming reactor (30). The plant also includes a carbonyl trap (70) upstream of the pre-reforming reactor (28), the carbonyl trap (70) being held at a temperature between a lower threshold value and an upper threshold value. The entire the length of the duct (72) is such that metal carbonyls are not formed. The inner wall of the duct (72) may be of a material which does not form metal carbonyls, or the duct (72) may be maintained at a temperature above the lower threshold value, so that metal carbonyls are not stable. This has been found to suppress contamination and deactivation of the reforming catalysts.
Abstract:
A catalyst structure (40) for a combustion reaction comprises a substrate (41) with a first end and a second end, a first portion (45) adjacent to the first end being devoid of any added catalytic material; a first coating (46) comprising palladium and/or palladium oxide, covers the entire length of the substrate, apart from the first portion (45). A second coating (47) comprising platinum covers a portion of the first coating (46) adjacent to the second end of the substrate (41). Each coating (46, 47) is porous and gas-permeable. This catalyst structure (40) is effective and durable, and enables high-temperature operation, as the catalyst does not deteriorate even at a temperature that may exceed 800° C.
Abstract:
A catalytic reactor (10) defines first and second flow channels (16, 17), with removable catalyst-carrying inserts (22, 24; 50) in each of those channels in which a reaction is to occur. The catalyst insert (22, 24; 50) comprises a plurality of foils (41, 42; 52) bonded together (40) and which subdivide the flow channel (16, 17) into a multiplicity of flow sub-channels. Along a major proportion (44) of the length of the catalyst insert (22, 24; 50), at least some of the foils (41, 42; 52) are not bonded together. This provides the insert with some resilience.
Abstract:
In a process for performing steam reforming of a feed gas (12) comprising methane in a reforming reactor (30) containing a reforming catalyst, to produce a synthesis gas, heat is provided to the reforming reaction by combustion (32) of a fuel in the presence of a combustion catalyst. The fuel consists at least partly of methane, and the process also comprises adding hydrogen to the fuel, and changing the proportion of hydrogen in the fuel in accordance with changes in the activity of the combustion catalyst. The hydrogen may be obtained from the synthesis gas, for example with a membrane (42). Adding hydrogen and optionally also carbon monoxide to the fuel can obtain a smoother and more consistent temperature distribution in the reactor (30) despite the decreasing activity of the combustion catalyst.
Abstract:
A gas stream is fed (48) into the catalytic reactor (50) and wherein a contaminant removal unit (75) is provided upstream of the catalytic reactor. The presence of a contaminant in the gas stream is detected by providing at least one contaminant trap (80) either upstream or downstream of the contaminant removal unit (75), and passing at least part of the gas stream through the or each contaminant trap (80) for at least some of the time. By monitoring (89, 92) the quantity of the gas that passes through each contaminant trap (80), and monitoring the presence of the contaminant material trapped in the contaminant trap (80), the presence and concentration of the contaminant in the gas stream can be assessed.
Abstract:
A chemical reactor (5) comprises a reactor block (10) defining multiple first and second flow channels (16, 17) which are arranged alternately within the block and separated by intervening walls (12, 13), such that fluids in the first and second flow channels can exchange heat through the intervening walls (12, 13). At least some of the intervening walls (13) define at least one channel (20) extending within the thickness of the wall (30) and communicating with an outside surface of the block (10), to accommodate a temperature sensor (25).
Abstract:
The catalytic reactor comprises a catalyst for converting synthesis gas to a product which is liquid or solid at ambient conditions. The catalyst is in the form of solid catalytic bodies without free liquid. Operation of the reactor is stopped by performing a shutting-in procedure. After the shutting-in procedure, operation of the reactor is restarted. The restarting comprises removing products such as hydrocarbons and water from the surface of the catalyst gradually so as to avoid damage to the pore structure of the catalyst by purging the catalyst with a flowing gas that contains a reducing agent e.g. hydrogen, for between 6 and 12 hours, at a temperature at or below the normal operating temperature of the catalyst.