CA2030915A1 - Reactor for catalytic gas reactions and/or physical separation processes - Google Patents
Reactor for catalytic gas reactions and/or physical separation processesInfo
- Publication number
- CA2030915A1 CA2030915A1 CA 2030915 CA2030915A CA2030915A1 CA 2030915 A1 CA2030915 A1 CA 2030915A1 CA 2030915 CA2030915 CA 2030915 CA 2030915 A CA2030915 A CA 2030915A CA 2030915 A1 CA2030915 A1 CA 2030915A1
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- CA
- Canada
- Prior art keywords
- gas
- reactor
- synthesis gas
- spherical
- reactor according
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- 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
- B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
- B01J8/0278—Feeding reactive fluids
-
- 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
- B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
- B01J8/04—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
-
- C—CHEMISTRY; METALLURGY
- 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
- C01B3/50—Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification
- C01B3/56—Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification by contacting with solids; Regeneration of used solids
- C01B3/58—Separation of hydrogen or hydrogen containing gases from gaseous mixtures, e.g. purification by contacting with solids; Regeneration of used solids including a catalytic reaction
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
- C07C29/15—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively
- C07C29/151—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases
- C07C29/152—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of oxides of carbon exclusively with hydrogen or hydrogen-containing gases characterised by the reactor used
-
- 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
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/00008—Controlling the process
- B01J2208/00017—Controlling the temperature
- B01J2208/00106—Controlling the temperature by indirect heat exchange
- B01J2208/00168—Controlling the temperature by indirect heat exchange with heat exchange elements outside the bed of solid particles
- B01J2208/00212—Plates; Jackets; Cylinders
-
- 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
- B01J2219/19—Details relating to the geometry of the reactor
- B01J2219/194—Details relating to the geometry of the reactor round
- B01J2219/1941—Details relating to the geometry of the reactor round circular or disk-shaped
- B01J2219/1942—Details relating to the geometry of the reactor round circular or disk-shaped spherical
Landscapes
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Combustion & Propulsion (AREA)
- Inorganic Chemistry (AREA)
- Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
- Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)
Abstract
ABSTRACT
With a reactor (1) for catalytic gas reactions and/or physical separation processes with a chiefly spherical pressure vessel foming the reactor shell (2) and a spherical catalyst bed (11) fitted inside the reactor shell, as well as a synthesis gas header fitted in the centre of the spherical catalyst bed, and with at least one synthesis gas outlet, the invention is to offer a solution simplifying such spherical reactors and, in particular, making it possible to adjust a defined flow pattern in the catalyst bed.
This is achieved by designing a spherical synthesis gas header (9) with a perforated outer surface (10) in order to bring about a defined synthesis gas flow, chiefly in a radial manner from inside to outside, and by designing the synthesis gas outlet with several gas outlets (12) evenly distributed over the reactor shell (2), with the gas-collecting tubes (15) penetrating the reactor shell (2).
Drawing to be published for this purpose: figure 1.
With a reactor (1) for catalytic gas reactions and/or physical separation processes with a chiefly spherical pressure vessel foming the reactor shell (2) and a spherical catalyst bed (11) fitted inside the reactor shell, as well as a synthesis gas header fitted in the centre of the spherical catalyst bed, and with at least one synthesis gas outlet, the invention is to offer a solution simplifying such spherical reactors and, in particular, making it possible to adjust a defined flow pattern in the catalyst bed.
This is achieved by designing a spherical synthesis gas header (9) with a perforated outer surface (10) in order to bring about a defined synthesis gas flow, chiefly in a radial manner from inside to outside, and by designing the synthesis gas outlet with several gas outlets (12) evenly distributed over the reactor shell (2), with the gas-collecting tubes (15) penetrating the reactor shell (2).
Drawing to be published for this purpose: figure 1.
Description
~ ~ V (~
~ eactor for catalytic c~as raac~;ons and/or phYsical separa~ion processes The invention concerns a reactor for catalytic gas reactions and/or physical separation processes, consisting of the ~ollowing:
a chiefly spherical pressure vessel forming the reactor shell, a spherical catalyst bed within said shell, a synthesis gas inlet with a synthesis gas header in the centre of the spherical catalyst bed, and at least one synthesis gas outlet.
Such a reactor is known from Italian patent application IT ~52 935, where the reactor has an outer, roughly spherical pressure shell, with a spherical catalyst bed placed between an inner and an outer shell, the latter being spherical and fitted with outlets. In the lateral outer shell section, there is a horizontal synthesis gas inlet, which penetrates the inner catalyst shell and connects further distributing tubes which, in turn, communicate with the spherical shell-shaped space between the outer catalyst shell and the reactor shell. In addition, the side opposite the synthesis gas inlet on the reactor shell is fitted with a horizontal synthesis gas outlet emanating from the inner space of the inner catalyst shell. The synthesis gas is fed, via synthesis gas inlet and distributing devices, into the spherical shell-shaped space, from which it flows, in an approximately radial manner, through the catalyst bed from the outside to the inside.
Reaction takes place in the catalyst bed, with the gas thereupon passing into the inner space of the inner catalyst shell in order to be removed through the synthesis gas outlet.
Compared to the commonly used cylindrical reactors, this conventional spherical reactor is chiefly distinguished by its ability to withstand considerably higher pressures, i.e. thinner walls may be used with similar reactor shell materials or, given roughly the same wall thickness materials of lower grade and strength may be employed. As a result, manufacturing costs can ba substentially reduced. However, the disadvantage of this conventional system consists in the relatively expensive and complicated reactor construction, because, in order to construct - : : ~ - :, , .
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~ eactor for catalytic c~as raac~;ons and/or phYsical separa~ion processes The invention concerns a reactor for catalytic gas reactions and/or physical separation processes, consisting of the ~ollowing:
a chiefly spherical pressure vessel forming the reactor shell, a spherical catalyst bed within said shell, a synthesis gas inlet with a synthesis gas header in the centre of the spherical catalyst bed, and at least one synthesis gas outlet.
Such a reactor is known from Italian patent application IT ~52 935, where the reactor has an outer, roughly spherical pressure shell, with a spherical catalyst bed placed between an inner and an outer shell, the latter being spherical and fitted with outlets. In the lateral outer shell section, there is a horizontal synthesis gas inlet, which penetrates the inner catalyst shell and connects further distributing tubes which, in turn, communicate with the spherical shell-shaped space between the outer catalyst shell and the reactor shell. In addition, the side opposite the synthesis gas inlet on the reactor shell is fitted with a horizontal synthesis gas outlet emanating from the inner space of the inner catalyst shell. The synthesis gas is fed, via synthesis gas inlet and distributing devices, into the spherical shell-shaped space, from which it flows, in an approximately radial manner, through the catalyst bed from the outside to the inside.
Reaction takes place in the catalyst bed, with the gas thereupon passing into the inner space of the inner catalyst shell in order to be removed through the synthesis gas outlet.
Compared to the commonly used cylindrical reactors, this conventional spherical reactor is chiefly distinguished by its ability to withstand considerably higher pressures, i.e. thinner walls may be used with similar reactor shell materials or, given roughly the same wall thickness materials of lower grade and strength may be employed. As a result, manufacturing costs can ba substentially reduced. However, the disadvantage of this conventional system consists in the relatively expensive and complicated reactor construction, because, in order to construct - : : ~ - :, , .
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2(~0~1~ 2 -the spherical shell-shaped synthesis yas distribution space, it ig n~cessary not only to provide a reactor shell, but also an outer catal~st shell as well as expensive gas distribution devices to feed the synthesis ~as from the centre into the spherical shell-shaped space. Above all, experience has shown that no clearly defined and practicable flow pattern develops in the catalyst bed, so that effecting synthesis gas reaction in the desired manner is rather difficult.
The aim of the invention is to simplify such a spherical reactor design and, in particular, -to provide ad~us-ting facilities or a defined flow pattern in the catalyst bed.
With a reactor of the type initially described, the objective of the invention is achieved in such a manner that, in order to ensure a de~ined ~low of the synthesis gas chiefly from inside to outside, the synthesis gas header is of a sherical design with a perforated outer sur~ace, and that the synthesis gas outlet consists of a plurality of evenly distributed gas vents and of gas-collecting tubes penetrating the reactor shell.
As a result of this design, the reactor is of a simpler design since it dispenses with extensive distributing devices for the synthesis gas and, apart from the reactor shell, does not require any further catalyst shells surrounding the catalyst bed. The specific design of the synthesis gas header and of the synthesis gas outlet with its plurality of gas vents permits a synthesis gas stream in the catalyst bed that can be adequately defined, the stream flowing radially from inside to outside, with the reaction chamber increasing in size towards the outside. These features represent a major advantage since the reaction process becomes more intense in the same direction and heat development increases likewise in exothermic reactions.
DE-PS 969635 describes a small gas burner to be fitted into a furnace and equipped with an ignition device. Said burner possesses a centric, spherical hollow body fitted inside.
.- :
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. .
:, ~ . , ,-).'31~ 3 _ DE-36 13903-~L shows a cylindrical reactor for catalytic dehydration processes, with gas feed frorn below, while DE-~S 24 24 664 showi.ng a spherical reac~or for synthesizing ammonia and methanol, this reactor housing a floating catalyst bed.
The invention provides for an optimized design in which each gas outlet has one gas-collecting body with a perforated contact surface, each gas-collecting body communicating with the catalyst bed and preferably being conceived as conical, basket-shaped, cylindrical or disk-shaped units. These shapes permit particularly large outlet cross sections to be provided on each gas-collecting body, thus ensuring an adequately defined synthesis gas flow pattern, chiefly in a radial manner from inside to ou-tside, while dead zones in the catalyst bed can be avoided.
It is of particular advantage i~ the gas-collecting tubes of the gas outlets communicate with a central gas header outside the reactor shell. l'his gas header is, therefore, fitted on ~he external surface of the reactor shell.
Another advantageous embodiment of the invention provides for a filled catalyst dome at the upper end of the reactor in order to equalize the volume when the reactor is started up for the first time. When using special catalysts, e.g. copper catalysts, which shrink by approx. 10% during the start-up phase of the reactor, it is possible to ensure, in a particularly simple manner as regards construction, that the catalytic material slips down by gravity, and that the inner chamber of the reactor is completely filled with catalytic material.
From a construction point of view, it is a great advantage for the synthesis gas inlet to be routed through the catalyst dome, in which case it is no longer necessary to provide an additional connecting flange on the spherical outer shell of the reactor.
Instead, the connecting flange of the catalyst dome can also be used for the synthesis gas inlet.
Another embodiment of the invention provides for the synthesis gas header to be additionally connected to a quench gas feed pipe, '~ ,;'' `' ' :
~" : ' , : . , : - . .
., . : , , .:
:
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thus permitting tempera~ure control, especially for cooliny to be effected within the reactor. ~lowever, it is also possible to fit a heat exchanger downstream of the reactor in order to effect heat exchange outside the reactor.
The reactor as envisaged by the invention is suited in particular for methanol or ammonia synthesis, CO conversion, Jnethanization and hydrogenation and/or selective hydrogenation of hydrocarbons or for packings subject to volume varia-tion such as activated carbon or zinc oxide, e.g. used for the adsorption of H2S, C02 and Hgt hydrogen sulphide, carbon dioxide and mercury.
In order to optimize the gas streams, t:he embodiment of the invention envisages for an inner sphere inside the synthesis gas header so as to guide the streams, the inner sphere being preferably fixed on retaining bars inside the header, thus defining the required flow pattern inside the gas header.
In order to optimize adaptation to the settling catalytic material, the embodiment of the invention provides for the synthesis gas header to be fitted to a chiefly centric gas feed tube, which, in turn, is mounted with an expansion joint.
This feature of the invention allows for the fact that, after a cer~ain period of operation (reduction of the catalyst), when the reactor is refilled with catalytic material, the latter compacts to a certain extent, thus settling, so that, possibly, cavities or empty spaces can develop in the "shadow" of the centric synthesis gas header as a result of the reactor material settling. Given the ~
high flow velocities, this would lead to the destruction of the ~-granulate, thus clogging the catalyst, a problem overcome by the longitudinal expansion joint which ensures optimal travel of the synthesis gas header.
Embodiments of the invention consist in the gas feed tube being fitted to the synthesis gas header from above, in line with the direction of gravity, and that longitudinal expansion is provided for in the storage area of the reactor shell and/or that the .. : .... , . ,. . ~ ;. ~ , . ~ .
: : : . : , -..
, ~ 5 -expansion joint is made of an elastic exparlsion element reinforeed by means os supporti.ng elements.
In order to op~imize outflows on the reactor shell, the in~ention also provides for multiple gas outlets on the inner surface of the reactor shell, as is commonly known, with the outlets constituting a web-type network of collecting tubes.
In accordance with the inventlon, another type of synthesis gas outflow consists in that the gas-collecting tubes on the inner surface of the reactor shell are designecl as collecting tubes adapted to the reactor shell perimeter and representing a section of a circle.
In the ollowing, the invention is explained in some detail with the help of the drawings mentioned below: :
Figure 1: a simplified sectional view of a reactor -Figure 2: an example of a modified embodiment in the same view as figure 1, as well as in ~ :
Figure 3: a sec~ional view of a simplified reproduction of a reactor in accordance with another embodiment of the invention Figure 4: a flow shee-t of a methanol synthesis unit using ~.
reactors in accordance with the invention as shown in figure 1.
The type of reactor for catalytic gas reactions, especially for synthesizing methanol and ammonia, for desulphurization, CO
conversion, methanization or selective hydrogenation is generally marked (1) in Figure 1. Reactor (1) first of all has a chiefly spherical pressure vessel foxming reactor shell (2), with a catalyst dome (3) being fitted in a pressure-proof manner on the upper side of said shell. Catalyst dome (3) is mounted with a catalyst inlet nozzle (4) and a manhole (5), its catalyst chamber being marked (5).
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~,J~ 6 -On the upper side of catalyst dome (3) and, consequently, aLso on the upper side of the reactor, the synthesis gas inlet is fitted, indicated as arrow (7) in figure 1. This gas inlet (7) is connected with tube (8), which penetra~es the catalyst dome (3) and communicates with the spherical s~nthesis gas header ~9) placed in the centre of spherical reactor shell (2). The synthesis gas header (9) has a perforated outer surface (10) and is placed in the centre of the spherical catalyst bed (11) enclosed by reactor shell (1).
The synthesis gas outlet consists of a plurality of gas vents (12), which are preferably arranged symmetrically on the inside of the reactor shell (2). The gas outlets (12) each possess a radial gas-collecting body (13) with perforated contact sur~ace (14) inside the reactor, collecting bodies (13) possibly being of different shapes. The left half of figure 1 additionally shows lyra-shaped collecting bodies (13a).
Of course, all gas-collecting bodies in a given reactor are of a standard shape in order to ensure a uniform gas stream in the reactor. Each gas-collecting body (13 or, respectively, 13a) is fitted with a gas-collecting tube (~5), which penetrates the reactor shell (2) and communicates with gas outlet tubes (16) outside the reactor shell (2). These gas outlet tubes (16) are preferably connected to a central gas outlet tube, which is not shown in detail here; the direction of the flow is indicated by arrows (16a).
On the underside of the reactor, there is a catalyst outlet nozzle (17), by means of which spent catalytic material can be removed.
On the catalyst dome (3), it is possible to fit an additional reduction device for catalytic material; in this drawing, this device is only indicated by connecting tube (18), which branches off from synthesis gas inlet (7) and ends in catalyst dome (3).
The configuration illustrated in Figure 1 contains two features:
on the one hand, there is a centre-guide ball (19) inside the synthesis gas header (9); on the other hand, the gas feed tube (8) : .:, . - .: . , :. , :
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2 ~ 1 5 - 7 ~
is fitted with a longitudinal exparlsiorl joint rna~ked (20), this section being designed as male/female sleeve.
In the embodiment shown in Figure 1, centre~guide ball (19) is firmly supported by means of retaining bars (45).
Figure 2 shows a modified embodiment in which the longitudinal expansion section (20a) is designed as a longitudinally variable tubing sys~em with an external supporting tube (47). The purpose of longitudinal compensators desiganted (20) or, respectively (20a) chiefly is to prevent the formation of a shadow-t~pe cavity behind the synthesis gas header (9a) (in Eigure 2, the latter is marked 6a) when the reactor has been filled with granulate and the catalyst inventory compacts during operation (e.g. reduction). In thîs reactor, the longitudinal compensator (20a) permits a - --downward motion of the synthesis gas header balls in order to fill any void.
In order to possibly change the position of ball (19a) in the interior of the gas header (9a), the inside ball (19a) can be provided with a guide rod (4~). In Figure 2, said movement is maxked by the double arrow (49); the arrow representing the downward movement of the synthesis gas header (9a) is shown as a double arrow (50).
Figure 3, finally, shows a different arrangement of inside ball (9b), which is guided from below. The gas feed pipe is marked (8b) and the guiding device with double arrow (50b). In this Figure, the longitudinal compensator is marked (51).
Figure 4 shows a reactor according to figure 1, installed in a methanol-synthesizing plant with three spherical reactors (1).
Fresh gas (21) and loop gas (22) are first mixed in gas stream (23). This stream is thereupon compressed in compressor (24) to form stream (25), the latter being added to CO gas stream (26) to form stream (27).
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:-:
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-2 02~ 8 Gas straem (27) is then pre-heated in a gas/gas heat exchanger (28) or, during the start-up phase, in a start-up heat exchanger (29), which is ~ed with an external heati.ng agent (30). The pre-heated synthesis gas stream (27) is then fed into the first spherical reactor (l); following reaction in the latter, the reaction gas is fed into a central gas discharge tube (16') via several gas outlet tubes (16). The methanol product gas in tube (16') is then cooled in the first medium-pressure steam generator (31), whose MD pipe is marked (32). Then the cooled methanol product gas (33) is fed to a second spherical reactor (1).
After entering the second spherical reactor (1) in which the methanol gas reaction takes place, the synthesized methanol product gas (34) is cooled again in a second medium-pressure steam generator (31a), in which medium-pressure steam (32a) is generated.
The cooled methanol product gas (34) can, thereupon, if needed, be fed into further reactors (13, depending on the desired reactor processes, until it is fed into the last spherical reactor (1), whose product gas (35) then passes gas/gas heat exchanger (2~) for cooling. The cooled product gas (36) can be cooled further in an air cooler (37) and, if required, in an additional condenser (38), whose cooling water tubes are marked ~39).
The cooled product gas (40) is then separated, preferably in a .
two-stage separator (41) in order to obtain crude methanol (42), loop gas (22), quench gas (43) and purge gas (44).
Of course, the invention is not confined to the embodiments exemplified in the attached drawings. The invention allows for further embodiments without abandoning the basic idea. For example, reactors as envisaged by the invention can also be used for other catalytic gas reactions and also for physical separation processes.
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The aim of the invention is to simplify such a spherical reactor design and, in particular, -to provide ad~us-ting facilities or a defined flow pattern in the catalyst bed.
With a reactor of the type initially described, the objective of the invention is achieved in such a manner that, in order to ensure a de~ined ~low of the synthesis gas chiefly from inside to outside, the synthesis gas header is of a sherical design with a perforated outer sur~ace, and that the synthesis gas outlet consists of a plurality of evenly distributed gas vents and of gas-collecting tubes penetrating the reactor shell.
As a result of this design, the reactor is of a simpler design since it dispenses with extensive distributing devices for the synthesis gas and, apart from the reactor shell, does not require any further catalyst shells surrounding the catalyst bed. The specific design of the synthesis gas header and of the synthesis gas outlet with its plurality of gas vents permits a synthesis gas stream in the catalyst bed that can be adequately defined, the stream flowing radially from inside to outside, with the reaction chamber increasing in size towards the outside. These features represent a major advantage since the reaction process becomes more intense in the same direction and heat development increases likewise in exothermic reactions.
DE-PS 969635 describes a small gas burner to be fitted into a furnace and equipped with an ignition device. Said burner possesses a centric, spherical hollow body fitted inside.
.- :
, '~ .:
, . - , - ::
. .
:, ~ . , ,-).'31~ 3 _ DE-36 13903-~L shows a cylindrical reactor for catalytic dehydration processes, with gas feed frorn below, while DE-~S 24 24 664 showi.ng a spherical reac~or for synthesizing ammonia and methanol, this reactor housing a floating catalyst bed.
The invention provides for an optimized design in which each gas outlet has one gas-collecting body with a perforated contact surface, each gas-collecting body communicating with the catalyst bed and preferably being conceived as conical, basket-shaped, cylindrical or disk-shaped units. These shapes permit particularly large outlet cross sections to be provided on each gas-collecting body, thus ensuring an adequately defined synthesis gas flow pattern, chiefly in a radial manner from inside to ou-tside, while dead zones in the catalyst bed can be avoided.
It is of particular advantage i~ the gas-collecting tubes of the gas outlets communicate with a central gas header outside the reactor shell. l'his gas header is, therefore, fitted on ~he external surface of the reactor shell.
Another advantageous embodiment of the invention provides for a filled catalyst dome at the upper end of the reactor in order to equalize the volume when the reactor is started up for the first time. When using special catalysts, e.g. copper catalysts, which shrink by approx. 10% during the start-up phase of the reactor, it is possible to ensure, in a particularly simple manner as regards construction, that the catalytic material slips down by gravity, and that the inner chamber of the reactor is completely filled with catalytic material.
From a construction point of view, it is a great advantage for the synthesis gas inlet to be routed through the catalyst dome, in which case it is no longer necessary to provide an additional connecting flange on the spherical outer shell of the reactor.
Instead, the connecting flange of the catalyst dome can also be used for the synthesis gas inlet.
Another embodiment of the invention provides for the synthesis gas header to be additionally connected to a quench gas feed pipe, '~ ,;'' `' ' :
~" : ' , : . , : - . .
., . : , , .:
:
:: - , .
. . ~ . ;. .
thus permitting tempera~ure control, especially for cooliny to be effected within the reactor. ~lowever, it is also possible to fit a heat exchanger downstream of the reactor in order to effect heat exchange outside the reactor.
The reactor as envisaged by the invention is suited in particular for methanol or ammonia synthesis, CO conversion, Jnethanization and hydrogenation and/or selective hydrogenation of hydrocarbons or for packings subject to volume varia-tion such as activated carbon or zinc oxide, e.g. used for the adsorption of H2S, C02 and Hgt hydrogen sulphide, carbon dioxide and mercury.
In order to optimize the gas streams, t:he embodiment of the invention envisages for an inner sphere inside the synthesis gas header so as to guide the streams, the inner sphere being preferably fixed on retaining bars inside the header, thus defining the required flow pattern inside the gas header.
In order to optimize adaptation to the settling catalytic material, the embodiment of the invention provides for the synthesis gas header to be fitted to a chiefly centric gas feed tube, which, in turn, is mounted with an expansion joint.
This feature of the invention allows for the fact that, after a cer~ain period of operation (reduction of the catalyst), when the reactor is refilled with catalytic material, the latter compacts to a certain extent, thus settling, so that, possibly, cavities or empty spaces can develop in the "shadow" of the centric synthesis gas header as a result of the reactor material settling. Given the ~
high flow velocities, this would lead to the destruction of the ~-granulate, thus clogging the catalyst, a problem overcome by the longitudinal expansion joint which ensures optimal travel of the synthesis gas header.
Embodiments of the invention consist in the gas feed tube being fitted to the synthesis gas header from above, in line with the direction of gravity, and that longitudinal expansion is provided for in the storage area of the reactor shell and/or that the .. : .... , . ,. . ~ ;. ~ , . ~ .
: : : . : , -..
, ~ 5 -expansion joint is made of an elastic exparlsion element reinforeed by means os supporti.ng elements.
In order to op~imize outflows on the reactor shell, the in~ention also provides for multiple gas outlets on the inner surface of the reactor shell, as is commonly known, with the outlets constituting a web-type network of collecting tubes.
In accordance with the inventlon, another type of synthesis gas outflow consists in that the gas-collecting tubes on the inner surface of the reactor shell are designecl as collecting tubes adapted to the reactor shell perimeter and representing a section of a circle.
In the ollowing, the invention is explained in some detail with the help of the drawings mentioned below: :
Figure 1: a simplified sectional view of a reactor -Figure 2: an example of a modified embodiment in the same view as figure 1, as well as in ~ :
Figure 3: a sec~ional view of a simplified reproduction of a reactor in accordance with another embodiment of the invention Figure 4: a flow shee-t of a methanol synthesis unit using ~.
reactors in accordance with the invention as shown in figure 1.
The type of reactor for catalytic gas reactions, especially for synthesizing methanol and ammonia, for desulphurization, CO
conversion, methanization or selective hydrogenation is generally marked (1) in Figure 1. Reactor (1) first of all has a chiefly spherical pressure vessel foxming reactor shell (2), with a catalyst dome (3) being fitted in a pressure-proof manner on the upper side of said shell. Catalyst dome (3) is mounted with a catalyst inlet nozzle (4) and a manhole (5), its catalyst chamber being marked (5).
,: . . - , .
. ' . ' :
~,J~ 6 -On the upper side of catalyst dome (3) and, consequently, aLso on the upper side of the reactor, the synthesis gas inlet is fitted, indicated as arrow (7) in figure 1. This gas inlet (7) is connected with tube (8), which penetra~es the catalyst dome (3) and communicates with the spherical s~nthesis gas header ~9) placed in the centre of spherical reactor shell (2). The synthesis gas header (9) has a perforated outer surface (10) and is placed in the centre of the spherical catalyst bed (11) enclosed by reactor shell (1).
The synthesis gas outlet consists of a plurality of gas vents (12), which are preferably arranged symmetrically on the inside of the reactor shell (2). The gas outlets (12) each possess a radial gas-collecting body (13) with perforated contact sur~ace (14) inside the reactor, collecting bodies (13) possibly being of different shapes. The left half of figure 1 additionally shows lyra-shaped collecting bodies (13a).
Of course, all gas-collecting bodies in a given reactor are of a standard shape in order to ensure a uniform gas stream in the reactor. Each gas-collecting body (13 or, respectively, 13a) is fitted with a gas-collecting tube (~5), which penetrates the reactor shell (2) and communicates with gas outlet tubes (16) outside the reactor shell (2). These gas outlet tubes (16) are preferably connected to a central gas outlet tube, which is not shown in detail here; the direction of the flow is indicated by arrows (16a).
On the underside of the reactor, there is a catalyst outlet nozzle (17), by means of which spent catalytic material can be removed.
On the catalyst dome (3), it is possible to fit an additional reduction device for catalytic material; in this drawing, this device is only indicated by connecting tube (18), which branches off from synthesis gas inlet (7) and ends in catalyst dome (3).
The configuration illustrated in Figure 1 contains two features:
on the one hand, there is a centre-guide ball (19) inside the synthesis gas header (9); on the other hand, the gas feed tube (8) : .:, . - .: . , :. , :
::
~, ~ . : . . ,: - . . . . .
2 ~ 1 5 - 7 ~
is fitted with a longitudinal exparlsiorl joint rna~ked (20), this section being designed as male/female sleeve.
In the embodiment shown in Figure 1, centre~guide ball (19) is firmly supported by means of retaining bars (45).
Figure 2 shows a modified embodiment in which the longitudinal expansion section (20a) is designed as a longitudinally variable tubing sys~em with an external supporting tube (47). The purpose of longitudinal compensators desiganted (20) or, respectively (20a) chiefly is to prevent the formation of a shadow-t~pe cavity behind the synthesis gas header (9a) (in Eigure 2, the latter is marked 6a) when the reactor has been filled with granulate and the catalyst inventory compacts during operation (e.g. reduction). In thîs reactor, the longitudinal compensator (20a) permits a - --downward motion of the synthesis gas header balls in order to fill any void.
In order to possibly change the position of ball (19a) in the interior of the gas header (9a), the inside ball (19a) can be provided with a guide rod (4~). In Figure 2, said movement is maxked by the double arrow (49); the arrow representing the downward movement of the synthesis gas header (9a) is shown as a double arrow (50).
Figure 3, finally, shows a different arrangement of inside ball (9b), which is guided from below. The gas feed pipe is marked (8b) and the guiding device with double arrow (50b). In this Figure, the longitudinal compensator is marked (51).
Figure 4 shows a reactor according to figure 1, installed in a methanol-synthesizing plant with three spherical reactors (1).
Fresh gas (21) and loop gas (22) are first mixed in gas stream (23). This stream is thereupon compressed in compressor (24) to form stream (25), the latter being added to CO gas stream (26) to form stream (27).
: . . .
:-:
- : : ,. ::: , :
-2 02~ 8 Gas straem (27) is then pre-heated in a gas/gas heat exchanger (28) or, during the start-up phase, in a start-up heat exchanger (29), which is ~ed with an external heati.ng agent (30). The pre-heated synthesis gas stream (27) is then fed into the first spherical reactor (l); following reaction in the latter, the reaction gas is fed into a central gas discharge tube (16') via several gas outlet tubes (16). The methanol product gas in tube (16') is then cooled in the first medium-pressure steam generator (31), whose MD pipe is marked (32). Then the cooled methanol product gas (33) is fed to a second spherical reactor (1).
After entering the second spherical reactor (1) in which the methanol gas reaction takes place, the synthesized methanol product gas (34) is cooled again in a second medium-pressure steam generator (31a), in which medium-pressure steam (32a) is generated.
The cooled methanol product gas (34) can, thereupon, if needed, be fed into further reactors (13, depending on the desired reactor processes, until it is fed into the last spherical reactor (1), whose product gas (35) then passes gas/gas heat exchanger (2~) for cooling. The cooled product gas (36) can be cooled further in an air cooler (37) and, if required, in an additional condenser (38), whose cooling water tubes are marked ~39).
The cooled product gas (40) is then separated, preferably in a .
two-stage separator (41) in order to obtain crude methanol (42), loop gas (22), quench gas (43) and purge gas (44).
Of course, the invention is not confined to the embodiments exemplified in the attached drawings. The invention allows for further embodiments without abandoning the basic idea. For example, reactors as envisaged by the invention can also be used for other catalytic gas reactions and also for physical separation processes.
:~ ::, , : : . :
' ' . ~: ~ ~ - ' : .
' ~ . ` . ' : -'
Claims (14)
1. Reactor for catalytic gas reactions and/or physical separation processes consisting chiefly of a spherical pressure vessel forming the reactor shell, a spherical catalyst bed fitted inside the reactor shell, a synthesis gas inlet with a synthesis gas header fitted in the centre of the spherical catalyst bed and at least one synthesis gas outlet, characterized in that in order to produce a defined flow pat-tern of the synthesis gas stream, chiefly radially from inside to outside, the synthesis gas header (9) is spherical with a perforated outer surface (10), and in that the synthesis gas outlet consists of a plurality of gas vents (12) evenly distributed over the reactor shell (2) with gas-collecting tubes (15) penetrating the reactor shell (2).
2. Reactor according to claim 1, characterized in that the gas vents (12) each have a gas-collecting body (13) with perforated contact area (14) connected to the catalyst bed (11).
3. Reactor according to claim 2, characterized in that the gas-collecting tubes (15) of the gas vents (12) are connected to a central gas outlet pipe (16') outside the reactor shell (2).
4. Reactor according to claim 1 or one of the following claims, characterized in that a catalyst dome (3) filled with catalytic material is provided to compensate for the volume reduced during the first startup of the reactor, said dome being fitted on the upper side of the reactor.
5. Reactor according to one of the preceding claims, characterized in that a ball (19) is fitted inside the synthesis gas header (9) in order to guide the gas flow.
6. Reactor according to one of the preceding claims, characterized in that in order to adjust the position of the inner centre-guide ball, a guide rod (48) is envisaged, said rod penetrating gas feed tube (8).
7. Reactor according to one of the preceding claims characterized in that the synthesis gas header (9) is fitted on a chiefly centric gas feed tube (8), which is equipped with a longitudinal expansion joint (20).
8. Reactor according to one of the preceding claims, characterized in that the expansion section is designed as an elastic compensator (46) reinforced by supporting elements to increase the structural strength (47).
9. Reactor according to one of the preceding claims, characterized in that several gas vents (12) are envisaged on the inner surface of the reactor shell (2), said gas vents having a web-type network of collecting tubes (13) as collecting bodies.
10. Reactor according to claim 9, characterized in that the gas-collecting tubes on the inner surface of the reactor shell are designed as collecting tubes (13a) adapted to the reactor shell perimeter and representing a sector of a circle.
11. Reactor according to one of the preceding claims, characterized in that the synthesis gas inlet (7,8) is designed to penetrate the catalyst dome (3).
12. Reactor according to one of the preceding claims, characterized in that the gas feed tube (8b) is, following the direction of gravity, fitted at the bottom of the synthesis gas header (9b), and in that a longitudinal expansion joint (51) is provided in the supporting area of the reactor shell (2b).
13. Reactor according to one of the preceding claims, characterized in that the synthesis gas header (9,9a,9b) is additionally connected to a quench gas feed.
14. Applications of the reactor according to one of the preceding claims, for methanol or ammonia synthesis, CO2 conversion, mechanization or hydrogenation and/or selective hydrogenation of hydrocarbons and/or adsorption with the aid of activated carbon, zinc oxide, etc.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DEP3939544.8 | 1989-11-30 | ||
| DE19893939544 DE3939544A1 (en) | 1989-11-30 | 1989-11-30 | Reactor for catalytic gas reactions or physical sepn. - has spherical catalyst bed with central distributor from which there is radial outward gas flow |
| DEG9006659.6 | 1990-06-13 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2030915A1 true CA2030915A1 (en) | 1991-05-31 |
Family
ID=6394470
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2030915 Abandoned CA2030915A1 (en) | 1989-11-30 | 1990-11-27 | Reactor for catalytic gas reactions and/or physical separation processes |
Country Status (2)
| Country | Link |
|---|---|
| CA (1) | CA2030915A1 (en) |
| DE (2) | DE3939544A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6083425A (en) | 1996-08-26 | 2000-07-04 | Arthur D. Little, Inc. | Method for converting hydrocarbon fuel into hydrogen gas and carbon dioxide |
| US6696027B1 (en) * | 1997-03-29 | 2004-02-24 | Ballard Power Systems Ag | Reformation reactor with catalyst charging |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6245303B1 (en) | 1998-01-14 | 2001-06-12 | Arthur D. Little, Inc. | Reactor for producing hydrogen from hydrocarbon fuels |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2989380A (en) * | 1953-11-24 | 1961-06-20 | Exxon Research Engineering Co | Apparatus for carrying out chemical reactions |
| DE2424664A1 (en) * | 1974-05-21 | 1975-11-27 | Chepos Z Chemickeho A Potravin | METHOD AND REACTOR FOR CARRYING OUT EXOTHERMAL CATALYTIC GAS REACTIONS |
| FI861694A (en) * | 1985-04-26 | 1986-10-27 | Air Prod & Chem | RADIALFLOEDESREAKTOR AV VERTIKALTYP. |
-
1989
- 1989-11-30 DE DE19893939544 patent/DE3939544A1/en not_active Ceased
-
1990
- 1990-01-20 DE DE9000603U patent/DE9000603U1/en not_active Expired - Lifetime
- 1990-11-27 CA CA 2030915 patent/CA2030915A1/en not_active Abandoned
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6083425A (en) | 1996-08-26 | 2000-07-04 | Arthur D. Little, Inc. | Method for converting hydrocarbon fuel into hydrogen gas and carbon dioxide |
| US6123913A (en) | 1996-08-26 | 2000-09-26 | Arthur D. Little, Inc. | Method for converting hydrocarbon fuel into hydrogen gas and carbon dioxide |
| US6207122B1 (en) | 1996-08-26 | 2001-03-27 | Arthur D. Little, Inc. | Method for converting hydrocarbon fuel into hydrogen gas and carbon dioxide |
| US6254839B1 (en) | 1996-08-26 | 2001-07-03 | Arthur D. Little, Inc. | Apparatus for converting hydrocarbon fuel into hydrogen gas and carbon dioxide |
| US6468480B1 (en) | 1996-08-26 | 2002-10-22 | Lawrence G. Clawson | Apparatus for converting hydrocarbon fuel into hydrogen gas and carbon dioxide |
| US6696027B1 (en) * | 1997-03-29 | 2004-02-24 | Ballard Power Systems Ag | Reformation reactor with catalyst charging |
Also Published As
| Publication number | Publication date |
|---|---|
| DE9000603U1 (en) | 1990-03-29 |
| DE3939544A1 (en) | 1991-06-06 |
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