Load following reactor system, related apparatus, and methods of operating the same

Abstract

A load following reactor system (150) and related apparatus for improved control of a reactor under varying loads is disclosed. The load following reactor (152) can be a pipe-cooled reactor for methanol synthesis. Reactants can be controlled by at least one valve element (160, 162) such that a portion of the reactants is provided to the reactor (152) through a reactor pipe (190) and a portion of the reactants is provided to the reactor (152) after being heated within a heat exchanger (156). The heated portion of the reactants can be provided to the reactor (152) after the pipe (190). The valve elements (160, 162) can be controlled in accordance with the temperature of the reactor (152) and / or the feed flow of the reactants to accommodate varying reactant flow to the temperature of the reactor (152).

Description

Technical Field

[0001] This disclosure relates to load-following reactors, associated components, and methods for implementing or operating them. The load-following reactor and associated components can be configured to perform chemical reactions and respond to changes in reactant flow rates, which is common when converting reactants to sources derived from renewable energy. The load-following reactor may be arranged with associated components that can facilitate heat transfer and / or thermal integration in response to changes in one or more reactants or process conditions, adapting to the process conditions (e.g., temperature) of the load-following reactor. Background Technology

[0002] A pressing dilemma in the global effort to provide clean and renewable energy is the inherent variability of wind, solar, geothermal, hydro, tidal, and other renewable energy sources, and the inability to store energy from renewable sources during peak production periods for later use during periods of high demand. Peak production periods for renewable energy, especially wind and solar, often do not match periods of high demand, and even when renewable energy is generating energy, a region's grid capacity to accommodate renewable energy may be limited by the slow turnaround or adaptability of existing power plants.

[0003] It is well known that, for example, during the hot summer months, peak energy demand occurs in the afternoon as people run air conditioning in their homes and offices, while peak wind power generation typically occurs in the evening or morning. Solar energy can only be collected during the day and under favorable weather conditions. Furthermore, renewable energy sources are often located far from consumers and transmission lines, complicating the transmission and efficient consumption of energy within existing power grids. Since 2005, energy production from wind and solar power has increased more than tenfold, making the challenge of successfully accommodating and utilizing renewable energy sources particularly prominent and expected to continue to grow in the foreseeable future.

[0004] The difficulty of storing energy during production and utilizing it during demand—for example, fossil fuels such as coal, oil, and natural gas have long been a major component of the global energy mix because these substances are stored as renewable energy sources, particularly solar energy, in the form of hydrocarbons—is a pressing concern. With global energy consumption projected to increase by 50% by 2050—nearly 300 trillion British thermal units more per year than current consumption—new models for the production, storage, and utilization of sustainable energy are urgently needed.

[0005] During periods of high demand, without an effective way to accommodate energy from renewable energy sources in the grid, and without viable storage options, such renewable energy is often cut back, wasted, or grounded. It is generally not feasible to simply reduce the output of benchmark energy sources or baseload power plants such as coal or nuclear power plants, as a rapid decrease followed by a rapid increase in the output of such plants may be operationally impractical.

[0006] In practice, these power plants are typically calibrated so precisely for specific production levels that changes in those levels, such as adapting to sudden and significant increases in wind power, can lead to catastrophic or costly equipment shutdowns or accidents, potentially taking days to recover. However, to avoid power outages, the available electricity in the grid must always equal the demand. Therefore, grid stability is a barrier to the widespread adoption of inherently variable renewable energy sources.

[0007] To address this issue, grid operators often employ flexible power plants known as peak load plants or "peak shaving units." These units typically operate for less time than base load plants, some as little as 250 hours per year, and are designed to rapidly boost load to 100% as quickly as possible to accommodate fluctuations in demand or production. Peak shaving units are usually deployed during periods of high or peak demand (such as summer months) and have recently been used to balance production from renewable energy sources. Compared to base load and peak load plants, load-following plants operate in direct response to changing electricity supply and demand.

[0008] Load-following power plants serve as balancing assets for renewable energy and are configured to operate at lower loads to offset the minute-by-minute fluctuations in renewable energy output. These plants typically use gas turbines or hydroelectric generators because of their ability to rapidly boost or reduce power generation, but at the cost of lower efficiency and higher capital and operating costs. In short, the primary approach to integrating renewable energy into the existing grid is to provide and utilize load-following or other flexible power plants (which are typically costly and inefficient) to reduce power production during peak renewable energy periods and increase it during periods of reduced renewable energy output.

[0009] An alternative to load-following power plants is to store energy during peak production periods for later use, but existing renewable energy storage methods are often too expensive, difficult to scale, or both. For example, gas in underground caverns (such as abandoned mines) could be compressed during peak production and then released via turbines during subsequent peak demand periods. This could also be done by pumping water, storing energy as the potential energy of water at higher elevations during peak production and regaining it as the kinetic energy of the water flowing back during peak demand periods. While this hydroelectric storage option is clearly limited by location, cost, and scalability, the vast majority of global energy storage capacity to date has been pumped-storage hydroelectric power.

[0010] For example, solar power plants can use thermal energy storage to store energy in the form of heat using materials such as molten salt, and release the energy later in the day. Alternatively, a pumped thermal energy storage system can be used, pumping heat from a cold storage to a hot storage, and then reversing the flow via a heat pump to extract the stored energy. Like hydroelectric storage options, thermal energy storage options are limited by location, cost, maintenance issues, and scalability. Thermal energy storage may be best suited for incremental and location-specific improvements, such as reducing inefficient energy use in office buildings, rather than large-scale energy storage options.

[0011] Lithium-ion batteries can store energy from renewable energy sources, but they are very expensive, costing between $380 and $900 per kilowatt-hour, especially at scale—the U.S. alone consumed approximately 100 trillion British thermal units (BTUs), or about 300 billion kilowatt-hours, in 2018. Therefore, providing energy storage for a large portion of a country's energy consumption via batteries is currently not economically feasible.

[0012] However, further energy storage methods include storing mechanical energy using flywheels or other mechanical devices such as concrete blocks, which are similarly limited by capital and operating costs. Another type of energy storage is chemical energy storage, particularly hydrogen storage, where excess electricity generated during peak renewable energy production is used to electrolyze water into oxygen and hydrogen, which is then used to generate electricity in fuel cells or gas turbines. Hydrogen can be stored in artificial containers, such as tanks (which present difficulties due to the small size of hydrogen molecules, making it difficult to escape through steel tanks), or in underground caverns such as salt domes. Hydrogen storage is inefficient and difficult to scale up due to the explosive nature of hydrogen, posing engineering challenges in the existing energy and petrochemical infrastructure of most developed countries.

[0013] U.S. Patent Application Publication 2019 / 0168155, published June 6, 2019, and U.S. Patent 8,506,910, filed April 20, 2012, describe the use of methanol to store energy from renewable energy sources, both of which are incorporated herein by reference in their entirety. Methanol is produced from syngas, which contains hydrogen obtained by electrolysis of water and carbon dioxide (CO2) obtained from any suitable source, including industrial point sources such as power plants. The syngas is reacted in a reactor with a suitable catalyst (such as a copper-zinc catalyst) with a mixture of methanol, water, byproducts, and unreacted feedstock in the reactor effluent, which can then be separated as described in U.S. Patent Application Publication 2019 / 0168155.

[0014] Methanol is advantageous over hydrogen, and therefore the "methanol economy" is advantageous over the "hydrogen economy" because methanol is an alternative chemical storage deployment method for renewable energy and is naturally a thicker, safer, and more readily contained liquid than hydrogen using existing energy and petrochemical infrastructure. Methanol also plays an important role in further chemical synthesis processes (including formic acid, formaldehyde, methyl tert-butyl ether, acetic acid, methyl methacrylate, dimethyl terephthalate, dimethyl carbonate (DMC), methylamine, chloromethane, methanethiol, dimethyl ether, and olefins (such as ethylene and propylene)) for use as a transportation fuel, in fuel cells, in wastewater treatment, and in power generation.

[0015] As described in U.S. Patent Application Publication No. 2019 / 0168155, the problem with producing methanol from renewable energy sources is that the equipment used to produce methanol from these sources must be adjusted accordingly to achieve optimal operation as the production of renewable energy varies or fluctuates. The production of renewable energy is proportional to the amount of hydrogen obtained through electrolysis. A corresponding or stoichiometric amount of CO2 from a suitable source can be supplied based on the variation in hydrogen production, resulting in variations in the amount of syngas supplied to the reactor.

[0016] Since the synthesis of methanol from CO2 and hydrogen is an exothermic reaction, and reactor conditions affect the efficiency and yield of the reaction, the reactor must be adapted to varying syngas loads to avoid adverse effects such as overheating (e.g., catalyst sintering, thermal runaway, and product degradation). Conversely, the adverse effects of operating below steady-state temperatures can lead to inefficient conversion and the accumulation of undesirable byproducts, such as those from endothermic reverse water-gas shift reactions.

[0017] It is well known that regulating reactor temperature to achieve steady-state operation (e.g., during startup) is challenging. Highly dynamic temperature control systems are designed solely to maintain steady-state operation. Operation under startup or non-steady-state conditions, which differ from steady-state conditions, presents further control challenges, leading to reduced selectivity and yield, and potentially catastrophic failures of the reactor vessel or related components and equipment.

[0018] The time from reactor start-up to "linear" or steady-state operation of such reactions can range from hours to days or weeks. Given the minute-by-minute fluctuations in renewable energy sources, such lengthy procedures for achieving linear or steady-state operation are unacceptable or economically infeasible, especially considering the reduced selectivity and productivity when the reactor is not operating in a steady state. The difficulty in regulating reactor temperature is partly due to the thermal inertia of the reactants and catalyst, as well as the reactor vessel itself, which complicates the rapid and precise regulation of the reactor temperature to the desired value. That is, the thermal inertia of the reactor system can slow down heat transfer relative to mass transfer, which is more significant in exothermic reactions, where fluctuations, including significant increases in mass flow rates, are expected. For example, when the load increases, heating at the top of the reactor may be slower than at the bottom due to the slower reaction rate at the top.

[0019] Existing equipment for regulating reactor temperature is often very complex and difficult to adapt to increases and decreases in flow rates associated with the load following the reactor. For example, some reactors are equipped with heating elements close to the catalyst bed. Other reactors may require modifications to the beds in multi-catalyst bed reactors and related equipment, such as supplying reactants to interbed heat exchangers capable of obtaining temperature profiles across certain catalyst beds.

[0020] Existing solutions to the problem of reactors struggling to adapt to changing process conditions are complex and lack the ability to rapidly raise or lower the overall reactor temperature. Furthermore, existing attempts to address this issue inefficiently add and remove heat, increasing operating expenses (OPEX) and placing additional economic pressure on renewable energy storage facilities. In many cases, operating such equipment using existing methods for regulating reactor temperature is economically unfeasible. The necessary maintenance of complex equipment provided by existing methods (such as heating coils, heat exchangers, or other heat transfer-related equipment used to attempt to regulate reactor temperature) further increases operating expenses, not to mention capital expenditures (CAPEX).

[0021] Given the exothermic nature of certain reactions (including methanol synthesis, methanation of CO, CO2 and H2, and others) that can be used in the load-following reactor systems and related equipment according to embodiments of this disclosure, maintaining control of the load-following reactor systems to avoid thermal runaway, catalyst sintering, and other high-temperature-related problems is also crucial.

[0022] Equipment including reactors for producing methanol from syngas derived from renewable energy sources can be configured as load-following reactors and equipment by adjusting conditions and equipment to adapt to the varying feedstock loads of renewable energy-based production. However, given the aforementioned challenges in adapting critical equipment, including reactors, to varying loads, particularly in the context of reactor temperature, there are few (if any) load-following applications with chemical energy storage.

[0023] In summary, there is a need for an improved, low-cost load-following reactor, related equipment, and operating methods to provide improved energy storage and adaptability to varying feed loads without significantly increasing operating expenses. Summary of the Invention

[0024] This disclosure discusses embodiments of load-following reactors, related facilities, and methods of operation thereof, which address the problem of suboptimal and inefficient operation of reactors with variable feedstocks or reactants under unsteady-state conditions. The load-following reactor system may include related equipment, such as thermally integrated equipment including a controller, to adjust and control the process conditions (e.g., temperature) of the load-following reactor in response to changes in the amount of reactants, thereby enabling the load-following reactor to adapt to different reactant flow rates and achieve steady-state or equilibrium operation more quickly.

[0025] A load-following reactor can be a reactor comprising tubes and / or a suitable catalyst (e.g., a methanol synthesis catalyst). The reactor may include one or more tubes to facilitate thermal integration within the reactor and catalyst. For example, one or more tubes may be configured to extend within the reactor body and from the beginning or starting portion of the tube through the catalyst or catalyst bed to the end portion of the tube. Reactants can pass through the tubes, thereby exchanging heat with the catalyst, reactor internals and / or reactants, byproducts, and products before being deployed to the catalyst by heating. The reactor may include a cyclone separator located at a turning point, such as the point where the reactants exit the tubes and then begin to flow directly through the reactor and / or catalyst bed. The cyclone separator ensures proper mixing of the reactants.

[0026] In exothermic reactions, supplying reactants through one or more tubes can advantageously extract heat from the ongoing reaction and preheat the reactants to the reaction temperature, thereby minimizing additional heat exchange. In endothermic reactions, providing one or more tubes can be configured to supply heat from the reactants to the ongoing reaction to promote the reaction. Associated thermal integration devices can be configured to vary the flow rate of reactants or heat exchange media through the tubes to achieve, reach, or maintain a target temperature.

[0027] In some embodiments, the flow rate of fresh reactants (e.g., H2 in a methanol synthesis environment) is increased based on their availability. For example, when excess electricity (such as electricity from renewable energy sources) is used in the electrolysis process, the flow rate of fresh H2 reactants may increase accordingly (and temporarily). The flow rate of CO2 generated, for example, in a power plant may be increased accordingly to accommodate the increased H2 and to provide an appropriate proportion of the composition of the synthesis gas (“syngas”) supplied to the specific catalyst used in the reactor.

[0028] Because increasing the reactant flow rate without corresponding changes in reactor conditions can adversely affect the conversion and selectivity of the ongoing reaction, the controller can be configured to regulate various process conditions to achieve the desired temperature in the reactor, thereby achieving optimal reactant conversion. When excessive power generation leads to increased H2 production and reactant flow rate, the controller can actuate valve elements used to control reactant deployment.

[0029] A suitable portion of the reactants can be transferred to the reactor's first feed line via valve elements, while the remainder can be conveyed through the reactor's second feed line. As the remainder of the reactants conveyed by the second feed line passes through the reactor's tubes under normal operating conditions, the first feed line can undergo further heat exchange to increase the temperature of the reactants in the first feed line. The first feed line can be connected to the reactor so that the reactants conveyed therethrough partially, substantially, or completely bypass these tubes. Furthermore, by reducing the proportion of reactants conveyed through the tubes, less heat is removed from the reactor (in exothermic operations).

[0030] When reactants are rapidly added and the operation is exothermic, the flow-guiding effect of the valve element can increase the temperature of the reactor itself and the reactants before the reaction, thereby enabling the reaction to reach a steady state quickly and seamlessly and improving inefficiency, such as the undesirable increase in the generation of byproducts due to mismatch between reactor conditions and flow rate.

[0031] In some embodiments, the valve element includes first and second valves located on each of the first and second feed lines of the reactor, thereby allowing the controller to precisely control the flow rate of the reactants. For example, all reactant feed may be allowed through the pipe, or all reactant feed may be diverted to the first feed line for further heat exchange and / or bypass the pipe, or any suitable distribution of the reactant feed may be performed as appropriate to achieve the desired process conditions in the reactor and associated equipment.

[0032] In some embodiments, further heat exchange associated with the first feed line is provided to occur in a dedicated first heat exchanger. The first heat exchanger may be configured to provide heat to the first feed line via any suitable heat exchange medium (e.g., steam). In some embodiments, the first heat exchanger may be integrated with the reactor output stream heat, thereby providing the first feed line with heat extracted from the heated reaction products. In other embodiments, the first heat exchanger may be adapted to remove heat from the reactants via any suitable heat exchange medium (e.g., cooling water).

[0033] When thermally integrated with the reactor outlet flow, the first heat exchanger can be arranged to receive heat from substantially the entire reactor outlet flow or from a side stream portion of the reactor outlet flow. In embodiments where the side stream portion of the reactor outlet flow heats the first feed line via the first heat exchanger, additional valve elements can be configured on the side stream portion for supplementary and fine-tuning process control. The cooled side stream portion can then rejoin the reactor outlet flow at any suitable location after the first feed line has been heated.

[0034] The reactants may be preheated by a second heat exchanger before any diversion to the first and second feed lines via at least one valve element occurs. The second heat exchanger may be thermally integrated with the reactor effluent line. In some embodiments, both the first and second heat exchangers are thermally integrated with the reactor effluent line. The first heat exchanger may be arranged between the reactor and the second heat exchanger, or it may be arranged downstream of the second heat exchanger relative to the reactor.

[0035] In some embodiments, the reactor outlet stream can be thermally integrated with any suitable process or arrangement; in one embodiment, the reactor outlet stream can provide a reboiler load for a downstream separation process, such as a fractionator that separates crude reaction products into refined products. This arrangement is particularly advantageous, for example, when producing synthetic methanol from renewable H2 and CO2, because the crude methanol product from the reactor may contain entrained water, CO2, CO, or other substances that must be fractionated to obtain methanol products of sufficient purity.

[0036] The efficiency of the reactor system and related equipment can be improved by providing a preliminary separation section and recirculation equipment. The reactor effluent can undergo heat exchange (e.g., cooling or condensation) downstream of the reactor section using a heat exchanger employing any suitable heat exchange medium (e.g., cooling water). Condensation of the products facilitates the separation of unreacted gaseous syngas (e.g., containing H2 and CO2) from the reaction products. Flash tanks or traps can separate remaining gaseous components (e.g., unreacted syngas and gaseous byproducts such as CO) from the condensed liquid products, while the gaseous components are recycled back to the reactor.

[0037] A hydrogen recovery unit can be provided to remove H2 from at least a portion of the separated gaseous components and to generate or extract waste gas streams, with the remaining syngas recycled to the fresh reactant feed. A compressor or circulator can be provided to compress at least a portion of the separated gaseous components, which are then supplied to the reactor along with the fresh reactant feed.

[0038] The condensed liquid product can be prepared for further processing in a downstream separation or recovery unit in a second flash tank, where the flash gas (including any remaining unreacted syngas, byproducts, or other light components) is sent to recycling, exhaust gas, battery limiting, or another process, and the remaining liquid product is processed for storage, battery limiting, downstream separation processes (such as fractionation), or further processing. In some embodiments, for example, crude methanol product can be provided to a further processing unit as a feedstock for formaldehyde or DMC synthesis processes. To more completely separate gaseous components from the condensed liquid product, the second flash tank can operate at a lower pressure than the first flash tank.

[0039] According to some embodiments of this disclosure, by providing a load-following reactor system, related equipment, and methods of operation thereof, the problem that existing chemical synthesis units are unsuitable for adapting to varying reactor feeds, particularly those that result in slow or difficult steady-state operation due to varying reactor feeds, is solved. The disclosed embodiments better enable reactor systems and related equipment to perform load following for energy storage and other applications without significantly increasing the CAPEX or OPEX of the system and process.

[0040] Variations of other methods, embodiments, and systems are described in more detail in the following discussion. Attached Figure Description

[0041] These and other features, aspects and advantages of the invention will become clearer and better understood based on the following description, the appended claims and the accompanying drawings.

[0042] Figure 1A This is a simplified diagram of a load-following reactor system and related equipment according to an embodiment of the present disclosure.

[0043] Figure 1B It is based on Figure 1A A simplified diagram of the load-following reactor and related equipment in an embodiment.

[0044] Figure 1C yes Figure 1B The load follows a simplified diagram of a variant of the reactor.

[0045] Figure 2A This is a simplified diagram of a load-following reactor and related equipment according to another embodiment of the present disclosure.

[0046] Figure 2B yes Figure 2A A simplified diagram of a variant of the load following the reactor and related facilities.

[0047] Figure 3 This is a simplified diagram of a load-following reactor and related equipment according to another embodiment of the present disclosure.

[0048] Figure 4 This is a simplified diagram of the operation method of the load-following reactor system and related equipment according to this disclosure.

[0049] The accompanying drawings are not necessarily drawn to scale, but are provided to offer a better understanding of the components and are not intended to limit the scope but rather to provide illustrative examples. The drawings illustrate exemplary configurations of the load-following reactor system and related equipment, and in no way limit the structure, configuration, or function of the load-following reactor system and related equipment according to this disclosure. Detailed Implementation

[0050] Different embodiments of the invention can be better understood from the following description with accompanying drawings, wherein the same reference numerals refer to the same elements.

[0051] While this disclosure is readily adaptable to various modifications and alternative constructions, certain illustrative embodiments are shown in the accompanying drawings and will be described below. However, it should be understood that this disclosure is not limited to the disclosed embodiments; rather, it covers all modifications, alternative constructions, combinations, and equivalents falling within the spirit and scope defined by this disclosure and the appended claims.

[0052] It should be understood that unless a term is defined in this patent to have the meaning described, the meaning of the term is not explicitly or indirectly limited to its simple or ordinary meaning.

[0053] Embodiments of the load-following reactor system, associated equipment, and operating methods of this disclosure advantageously allow the reactor system to more effectively load-follow applications, including but not limited to energy storage, by enabling the reactor and associated equipment to easily and quickly adapt to changing process conditions, thereby minimizing inefficiencies caused by process condition mismatches.

[0054] Because reactor dimensions are typically designed for a specific set of optimized kinetic parameters to optimize yield, conversion, and selectivity, operating the reactor at flow rates different from the design values ​​requires corresponding changes to other kinetic parameters of reactor operation. For example, as reactant flow rates change, the load-following reactor system embodiments of this disclosure can facilitate the conditioning of the reactor temperature to a targeted value to quickly achieve steady-state operation, preferably at reaction equilibrium, thereby maintaining adequate reactant conversion and minimizing operating expenses (OPEX).

[0055] In one exemplary embodiment, as the renewable electricity load increases, leading to an increase in reactant flow rate, and consequently an increase in energy and reactant load, the reactor temperature can be adjusted upwards to a higher temperature and a higher equilibrium constant. The increased temperature results in a faster reaction rate and an equilibrium constant that compensates for the shorter residence time of reactants in the reactor. In exothermic reactions, such as methanol synthesis, higher temperatures may increase conversion and decrease selectivity, thereby enabling the reactor system and associated equipment to handle increased reactant flow rates.

[0056] Similarly, as the reactant flow rate decreases, the reactor temperature can be adjusted downwards accordingly, reflecting a lower conversion rate and a longer residence time. This reduces OPEX, improves selectivity, discourages side reactions (such as reverse water-gas shift reactions), and minimizes product degradation through byproduct and unreacted syngas separation and recycling processes. This allows embodiments of the reactor system to follow reductions in energy and reactant loads. Process conditions (e.g., pressure, recirculation rate, and individual reactant concentrations) can be similarly adjusted as needed, or other variations can be applied.

[0057] Embodiments of the load-following reactor system and related equipment disclosed herein can regulate the reactor temperature to, and / or based on, a non-uniform temperature distribution on the reactor that defines a peak shape. For example, when the load is low (i.e., the reactant flow rate is reduced relative to the baseline), the reactor temperature can be defined with a peak shape distribution having a peak near the top of the reactor. Conversely, when the load is high (i.e., the reactant flow rate is increased relative to the baseline), the reactor temperature can be defined with a peak shape distribution having a peak near the bottom of the reactor. The dynamic characteristics of the peak shape distribution contribute to the thermal inertia of the reactor and reactants. Embodiments of the load-following reactor system disclosed herein advantageously reduce the time required to overcome the thermal inertia of the reactor and catalyst, as well as the time required to redistribute heat within the reactor and thus reposition the temperature distribution of the reactor. By doing so, heat transfer occurring within the reactor can be controlled more quickly and precisely.

[0058] Figure 1AA simplified process flow diagram illustrates a load-following reactor system and associated equipment according to one embodiment. Reactor system 100 may include reactor section 150, feed section 110, preliminary separation section 170, and hydrogen recovery unit 120. In an exemplary but non-limiting embodiment, reactor system 100 is configured as a methanol synthesis apparatus, wherein feed section 110 provides fresh H2 feed 103 and fresh CO2 feed 101. The fresh H2 feed can be obtained from one or more electrolysis processes, whereby renewable electrical energy is used to produce H2 and O2 from water, or obtained and purified for a second industrial process. The fresh CO2 feed 101 can be obtained from any suitable source, such as a point source from an industrial or fossil fuel-based power plant, or obtained and purified from a diluted atmospheric source. The fresh H2 and CO2 together define a syngas mixture suitable for producing methanol using a suitable catalyst, such as conventional Cu-Zn-based catalysts, or rarer noble metal catalysts known to those skilled in the art.

[0059] The combined fresh feed stream 105 is combined with the recirculated syngas stream 117 and compressed to a suitable reaction pressure in the syngas compressor 104. The compressed combined syngas stream 107 can be combined with the compressed recirculated stream 113 before the combined reaction stream 109 is provided to reactor section 150, as will be described in more detail herein. Reactor section 150 can be arranged as a load follower reactor for converting syngas, which substantially comprises H2 and CO2, into methanol products. While fresh H2 and CO2 are described in the disclosed embodiments, it should be understood that the disclosed embodiments are merely exemplary and any suitable reaction suite can be used. For example, conventional syngas comprising a mixture of H2, CO2, and CO can be used similarly and effectively.

[0060] The reactor effluent or product stream 171 can be conveyed from reactor section 150 to heat exchanger 174. Heat exchanger 174 can be arranged as a condenser and can be cooled using any suitable heat exchange medium provided at stream 173. The heat exchange medium can be cooling water or any other suitable medium. Heat exchanger 174 can be configured to condense reactor effluent or product stream 171, such that the condensed product stream 175 is conveyed to a first flash tank or trap 176.

[0061] The first flash tank 176 is configured to perform a first separation of components in the reactor effluent, which, upon exiting reactor section 150, comprises a combination of methanol products, byproducts, and unreacted syngas, each of which may have different thermodynamic properties. By conveying the condensate stream 175 to and through the first flash tank 176, non-condensable or non-condensable fluids (e.g., unreacted syngas containing H2, CO2, and CO) can be substantially removed by the first separation stream 179.

[0062] The unreacted syngas can be delivered to the hydrogen recovery unit 120 via the second separate gas stream 115. Alternatively, the unreacted syngas can be delivered to the syngas circulator or compressor 106 via the third separate gas stream 111 under the control of valve 112. The unreacted syngas in the third separate gas stream 111 can be repressurized to, for example, the desired operating pressure of the reactor section 150, and then combined with the combined syngas stream 107.

[0063] Hydrogen recovery unit 120 can extract hydrogen from unreacted syngas and other components in the first separated gas stream 179. Hydrogen recovery unit 120 can generate waste gas stream 119, which may be discharged into the atmosphere, burned, moved to an equipment area, stored, burned, or otherwise consumed in a furnace or other equipment, or otherwise disposed of. The composition of waste gas stream 119 can be selected based on applicable regulations and process conditions. Hydrogen recovery unit 120 can further provide a recirculated syngas stream 117 to be combined with the combined fresh feed stream 105, and then recirculated to reactor section 150.

[0064] The hydrogen recovery unit 120 can be any suitable hydrogen recovery device, utilizing known technologies such as pressure swing adsorption (SPA) units, membrane purification units, cryogenic separation units, or others. The reactor system 100 may include the hydrogen recovery unit 120 in any suitable location or configuration, designed based on any suitable process constraints and taking into account downstream or alternative H2 disposal, current H2 production levels, or other factors.

[0065] The remaining condensate after separation in the first flash tank 176 can be transferred to the second flash tank 180 via the liquid effluent line 177. The second flash tank 180 similarly separates the liquid product from the waste gas still entrained within the liquid product. The second flash tank 180 can operate under any suitable process conditions, and in embodiments, it can operate at a lower pressure than the first flash tank 176 to achieve more complete separation of the entrained gaseous components. The separated gaseous components can be removed via the second waste gas stream 181, which, like waste gas stream 119, can be discharged into the atmosphere, burned, moved to an equipment area, stored, burned, or otherwise consumed in a furnace or other equipment, or otherwise disposed of.

[0066] The remaining liquid product after separation by the second flash tank 180 may include an enhanced portion of the reaction products (e.g., crude methanol when syngas is the reactant) and may be disposed of in any suitable manner. For example, the reaction products in stream 183 may be stored, provided to a facility area, further processed in a downstream chemical processing unit, or further refined in the separation section. The downstream separation section may be a separation unit as described in U.S. Patent Publication No. 2019 / 0168155 (published June 6, 2019, to whom this disclosure is assigned, the entire contents of which are incorporated herein by reference).

[0067] from Figure 1B Reactor section 150 is shown in more detail below. Reactor section 150 may contain a combined reaction stream 109, which may contain fresh feed and recycled reactants. In an embodiment of methanol synthesis reaction, the combined reaction stream 109 may contain synthesis gas with appropriate fractions of H2, CO, and / or CO2 based on desired reaction conditions and desired catalyst.

[0068] exist Figure 1B In the embodiments described herein, the combined reactant stream 109 is thermally integrated with the reactor effluent in a heat exchanger 155. In embodiments of an exothermic methanol synthesis reaction, the heat carried by the hotter reactor effluent can preheat the combined reactants to a suitable temperature based on reactor conditions. Heat exchanger 155 and all heat exchangers described herein can be any suitable heat exchanger configured to have any suitable characteristics and operate in any suitable manner. For example, heat exchanger 155 can be a parallel and counter-flow heat exchanger, a finned and finless tube heat exchanger, a shell-and-tube heat exchanger, a U-tube heat exchanger, a single-pass straight and two-pass straight heat exchanger, a plate and frame heat exchanger, a plate-fin heat exchanger, a microchannel heat exchanger, or others.

[0069] The preheated combined reactant stream 121 can be transferred between the first reactor feed line 123 and the second reactor feed line 125 via valve element 162. The first reactor feed line 123 can be arranged to receive further preheating or heat exchange and can be configured to connect to reactor 152 at the top 154. The first reactor feed line 123 can support valve element 160. The second reactor feed line 125 supports valve element 162 and can be configured to connect to reactor 152 at the bottom 153. In the depicted embodiment, reactor 152 can be a tube-cooled reactor comprising a tube 190 extending through its body as described in U.S. Patent Application Publication No. 2019 / 0168155. That is, tube 190 can extend from the bottom 153 to the top 154 ​​of reactor 152 in a generally countercurrent manner relative to the flow of reactants, byproducts, and products flowing through reactor 152.

[0070] Valve elements 160 and 162 can be any suitable valve element, including but not limited to linear motion valves (including gate valves, globe valves, diaphragm valves, pinch valves, and needle valves), rotary valves (including ball valves, plug valves, and butterfly valves), self-actuated valves such as check valves and pressure reducing valves, or other valves. Valve elements 160 and 162 may include an actuator (not shown) configured to cooperate with a controller to regulate valve elements 160 and 162 as needed. Valve elements 160 and 162 may be valves of the same type and size, or they may be different.

[0071] The reactants fed to reactor 152 via the second reactor feed line 125 can flow upwards from the bottom 191 of pipe 190, corresponding to the bottom 153 of reactor 152, absorbing heat from the exothermic reaction occurring in the body of reactor 152. By the time the reactants reach the top 192 of pipe 190, corresponding to the top 154 ​​of reactor 152, the reactants may have already experienced a significant temperature rise. Near or at the top 154 ​​of reactor 152, the heated reactants can exit pipe 190 and enter the body of reactor 152, thereby contacting the catalyst arranged within the reactor body.

[0072] The catalyst can be any suitable catalyst. In embodiments of the methanol synthesis reactor, the catalyst can be, for example, a suitable Cu-Zn-based catalyst known to those skilled in the art. The catalyst can further be arranged in any suitable form and arrangement. In some embodiments, reactor 152 can define one or more catalyst beds on which a certain amount of catalyst is arranged and through which tubes can pass to obtain the desired heat transfer from each of the one or more catalyst beds.

[0073] In other embodiments, the catalyst may be packed within the reactor body in monomeric form. The catalyst may comprise any suitable matrix, and the packing may comprise any suitable structure to enhance the contact between the reactants and the catalyst as the reactants flow downwards from top 154 ​​to bottom 153. It should be understood that the depicted embodiments are merely exemplary, and any suitable reactor arrangement may be used.

[0074] The first reactor feed line 123 can be configured to directly transfer reactants transferred therethrough to the top 154 ​​of reactor 152, and by bypassing the pipe, the step of heat exchange with the ongoing reaction participants can be skipped. In exothermic processes such as the synthesis of methanol from syngas, skipping the step of extracting heat from the ongoing reaction into the reactants can be used to increase the reactor temperature and temperature distribution, as heat accumulates in the reactor body, catalyst, and reaction participants. Thus, transferring a portion of the reactants through the first reactor feed line 123 can at least temporarily and to some extent sacrifice reaction efficiency to increase the reaction rate, particularly accelerating the process to steady-state operation.

[0075] The reactants transferred to the top 154 ​​of reactor 152 via the first reactor feed line 123 can be preheated in heat exchanger 156 outside of the internal heat exchange process of the reactor. Heat exchanger 156 can be thermally integrated with reactor effluent 127 to provide heat to the first reactor feed line 123, thereby minimizing waste heat and reducing the overall OPEX and emissions of reactor system 100.

[0076] In some embodiments, heat exchanger 156 may be configured and operated to maintain a constant temperature, independent of the operation of valve elements 160, 162. By maintaining the heat exchanger 156 at a constant temperature, thermal inertia in reactor 152 and associated equipment can be minimized and mitigated, as the load follows reactor system 100 to adapt to load changes, for example, by simultaneously changing the temperatures of the reactants and reactor 152.

[0077] Furthermore, by maintaining the heat exchanger 156 at all times or substantially continuously, the load-following reactor system 100 can respond quickly and flexibly to load changes, thereby improving the flexibility and responsiveness of the load-following reactor system 100. As discussed herein, these advantages are advantageously achieved by providing heat exchangers and corresponding equipment compared to non-load-following process designs.

[0078] In other words, the load-following reactor system and related equipment and embodiments of this disclosure address the thermal inertia problem in reactors undergoing load changes in a simpler, smoother, and less costly manner than existing solutions. The load-following reactor system and related equipment and embodiments further enable equipment working in conjunction with the reactor system to operate momentarily or discontinuously, thereby minimizing OPEX and activating only when it is economically advantageous to handle reactant flow and product disposal.

[0079] although Figure 1B and 1C The diagram shows that heat exchanger 156 is heated on reactor effluent line 127, but it should be understood that heat exchanger 156 can be heated alternatively or additionally by external devices, including but not limited to electric coils, combustion heat from fuel gases (such as excess H2, CO or methanol), or by a suitable heat exchange medium (such as steam).

[0080] In an embodiment of the exothermic methanol synthesis reaction, the heated reactor effluent 127 can be conveyed to heat exchanger 156 to provide heat to the reactants transferred through the first reactor feed line 123 by valve elements 160, 162. A partially cooled reactor effluent can be conveyed at stream 133 to heat exchanger 155 for further cooling of the incoming reactants. The further cooled reactor effluent can then be conveyed out of reactor section 150 at stream 171. Specifically, the amount of heat transferred between reactor effluents 127, 133 and the reactants, as well as the residual heat in reactor effluents 127, 133, 171, is controlled by the extent to which the combined reaction stream 109 is transferred to the first reactor feed line 123.

[0081] The reactor system 100 may be equipped with a controller configured to determine, based on the dynamics and needs of the process at any given time, the appropriate proportion of the combined reactant stream 109 transferred through the first reactant feed line 123 compared to the second reactant feed line 125. The controller may receive signals indicating process conditions (e.g., flow rate, composition, temperature, and pressure) and automatically determine the appropriate action of valve elements 160, 162.

[0082] For example, the controller can receive a signal that the flow rate of the fresh H2 stream 103 has increased. Based on the degree of increase in the fresh H2 stream 103, the controller can request that a portion (e.g., 50% by volume) of the combined reactant stream 109 be transferred to the first reactor feed line 123 to increase the reactor temperature based on the increased reactant flow rate. This can be achieved by sending a signal to the actuator to adjust the valve elements 160, 162 accordingly. The controller can also request that the flow rate of the fresh CO2 stream 101 increase stoichiometrically as the fresh H2 stream 103 increases.

[0083] It should be understood that the controller can respond to any process condition by any suitable adjustment. For example, the extent to which the flow rate of fresh H2 stream 103 increases or decreases compared to the second reactor feed stream 125 may require any suitable proportion of reactants to be transferred to the first reactor feed stream 123, ranging from 0% to 100%, by volume, mass or other means.

[0084] The controller can further or alternatively influence the operation of any suitable process conditions, such as the pressure to which the reaction streams 105 and 111 are raised by the compressors 104 and 106, the amount of hydrogen extracted by the hydrogen recovery unit 120, the heat extracted from the reactor effluent, or others.

[0085] exist Figure 1B In the variant of reactor stack 150 shown, Figure 1C The reactor section 175 depicted may similarly incorporate a reactor 152, as well as a first heat exchanger 155 and a second heat exchanger 156 as previously described. In addition to the first heat exchanger 155 and the second heat exchanger 156, the reactor section 175 may incorporate a third heat exchanger 158. In the illustrated embodiment, the third heat exchanger 158 is shown receiving the reactor effluent stream 129 prior to the first heat exchanger 155; however, this embodiment is merely exemplary, and the third heat exchanger 158 may be arranged downstream of the first heat exchanger 155, upstream of the second heat exchanger 156, or at any suitable location.

[0086] The third heat exchanger 158 may be arranged to extract heat from the reactor effluent 129 for any suitable purpose. In some embodiments, the heat extracted from the reactor effluent 129 in the third heat exchanger 158 may be provided to downstream or unrelated processes, which are different from the reactants in the preheating reactor section 175.

[0087] An exemplary process that can utilize the extracted heat is to provide a reboiler load to a fractionation column downstream of the initial separation section 170. The fractionation column can be used to separate the product methanol from contaminants such as water, as described in U.S. Patent Application Publication No. 2019 / 0168155. The third heat exchanger 158, as shown, can alternatively be used to provide heat for such a process, independent of the use of the first heat exchanger 155 and the second heat exchanger 156, as shown. The use of the third heat exchanger 158 can also be controlled and enhanced by a controller.

[0088] In addition to the first valve element 162 disposed on the second reactor feed line 125, a second valve element 160 is disposed on the first reactor feed line 123. By providing the additional valve element 160, the controller can exert an additional degree of precise control over the amount of reactants transferred between the first reactor feed line 123 and the second reactor feed line 125. For example, the second valve element 160 can completely block the flow of reactants to the first reactor feed line 123 as needed, and the valve element 162 can completely block the flow of reactants to the second reactor feed line 125 as needed, and control any ratio between the two.

[0089] A variant of reactor section 150 in Figure 2A and 2B As shown in the embodiment. The reactor section 250 can be similarly integrated into Figure 1A In the reactor system 100 shown, reactor section 250 may include reactor 252 having a top 254 and a bottom 253, and may be configured with one or more pipes extending through its body. The combined reactant feed stream, as previously described, may be arranged to be transferred to the first reactor feed line 223 to a desired extent, compared to the second reactor feed line 225. The combined reactor feed 109 may be preheated in the first heat exchanger 255 before being transferred. The first reactor feed line 223 may be arranged to provide the transferred reactants to the top 254 of reactor 252 after preheating in the second heat exchanger 256, allowing for thermal integration with the reactor effluent.

[0090] The second heat exchanger 256 can extract heat only from the desired proportion of the reactor effluent 227. A third valve element 230 and its corresponding actuator can be controlled by a controller to transfer the desired amount of reactor effluent 227 to the second heat exchanger 256 via line 231. The remaining portion of reactor effluent 227 can be conveyed to the first heat exchanger 255 via line 229. After the desired heat has been extracted from the reactor effluent via line 231, it is conveyed back to the remaining portion of reactor effluent 229 via line 232. Figure 2A In the depicted embodiment, the remainder of reactor effluent 229 may receive a diversion section 232 or rejoin the diversion section 232 before heat is extracted from reactor effluent line 233 in the first heat exchanger 255. Reactor effluent line 271 can ultimately be delivered from reactor section 250 to the aforementioned downstream process.

[0091] The amount of reactor effluent 227 transferred by the third valve element 230 can be determined by the controller based on the proportion of reactant feed 109 transferred from the second reactor feed line 225 to the first reactor feed line 223 via the first valve element 260 and the second valve element 262. As previously mentioned, the first valve element 260 and the second valve element 262 can be driven by the controller to provide any desired diversion of the combined reactor feed 109 to the reactor feed lines 223, 225.

[0092] In some embodiments, a smaller proportion of the combined reactor feed 109 transferred to the first reactor feed line 223 may correspond to a smaller proportion of the reactor effluent 227 transferred to the heat exchanger 256 by the third valve element 230. In other embodiments, the controller increases the amount of reactor effluent 227 transferred to the heat exchanger 256 primarily based on when a rapid increase in reactor temperature by a certain amount is needed. Similar to the foregoing embodiments, the heat exchanger 256 can be kept warm for all or substantially all of the time the load-following reactor system is operating, to increase the flexibility and responsiveness of the load-following reactor system, and can be kept warm by any suitable means as described above regarding the heat exchanger 156.

[0093] Figure 2B A variation is shown. (Compared to) Figure 2A Similar to the embodiments, the temperature and / or other conditions of reactor 252 can be controlled by transferring a portion of the combined reactor feed 109 through the first reactor feed line 223, compared to the second reactor feed line 225. A heat exchanger 256, which can further preheat the transferred portion of the reactants in the first reactor feed line 223, can directly heat the reactants via heating elements or heat from an external source, or heat a portion of the reactor effluent line 227, which can be switched by a third valve element 230 according to the controller's instructions in response to one or more indications of process conditions, such as reactor temperature, pressure, reactant flow rate, or others.

[0094] and Figure 2A In a variant, a portion of the reactor effluent 227 transferred through heat exchanger 256 in line 231 can be rejoined with the remainder of the reactor effluent line via line 234 downstream of heat exchanger 255. The recombined reactor effluent stream 235 can then be transported outside reactor section 250. In this embodiment, the heat exchanged in the two heat exchangers 255, 256 can be fine-tuned and adjusted by a controller so that the temperature distribution of reactor 252 or any other suitable process conditions can be adjusted based on another varying process condition (e.g., the flow rate of reactants such as H2).

[0095] Figure 3Another embodiment of the load-following reactor and associated equipment is shown. Similar to the foregoing embodiments, reactor section 350 may include reactor 352 and at least one heat exchanger 355, 356 configured to preheat the combined reactor feed 109 based on and in response to changing process conditions. Heat exchanger 356 may be arranged as a thermally integrated heat exchanger as in previous embodiments, reactor effluent line 327 for preheating the reactants, and cooled reactor effluent line 371 exiting from reactor section 350 to downstream processes.

[0096] Heat exchanger 356 can be configured to use a heat exchange medium other than the reactants and effluents of reactor section 350. In some embodiments, a suitable heat exchange medium is supplied to heat exchanger 356 at line 331 and exits at line 333. The heat exchange medium can be steam at any suitable pressure, such as low-pressure (LP) steam, medium-pressure (MP) steam, high-pressure (HP) steam, ultra-high-pressure (SHP) steam, or others. The heat exchange medium can be waste heat from a separation process. In other embodiments, or additionally, the heat exchange medium can be supplied by an electric heater.

[0097] As previously described, reactor section 350 may be configured to transfer a desired proportion of the combined reactant feed 109 to an additional preheating process in the first reactor feed line 323 via the actuation of one or both of the first valve element 360 and the second valve element 362, thereby being transferred to the top 354 of reactor 352. For example, when process conditions such as the flow rate of fresh H2 feed change, the controller may detect that the temperature, pressure, or other process conditions of reactor 352 or another device are unsuitable or mismatched with the changed process conditions.

[0098] Because in some embodiments, the increased renewable electrical energy is used to generate H2 from water electrolysis, the reactor temperature may be too low to achieve efficient and balanced steady-state operation when the stoichiometric CO2 flow rate is increased. Compared to existing methods of operating reactors (which typically involve slow and / or inefficient adjustments to process conditions in an attempt to achieve steady-state operation), the reactor systems and associated equipment of the embodiments of this disclosure provide improved processes for adjusting process conditions and have simplified process planning. While an increase in the stoichiometric CO2 flow rate has been described, it should be understood that the load-following reactor system and associated equipment can utilize any suitable reactant ratios and flow rates. For example, excess H2 can be used to increase the reaction rate and improve CO2 conversion.

[0099] Figure 4A method for operating a reactor system and related equipment according to an embodiment of this disclosure is illustrated. The method 400 for operating load following the reactor and related equipment includes a first step 402 of detecting one or more process conditions. This particularly includes detecting or predicting the flow rate of reactants, such as H2. A second step 404 includes determining an appropriate change in one or more conditions, which may be based on and in response to the changes in process conditions detected in the first step 402. For example, a controller may detect that, based on an increased H2 flow rate, the reactor temperature should, for example, increase by 10°C to achieve optimal operation at the increased flow rate. In one embodiment, a target temperature may be determined based on the reactant flow rate. Multiple conditions may need to be changed. An increase in the stoichiometry of fresh CO2 may need to be achieved in conjunction with an increase in reactor temperature, a change in compressor pressure, or others.

[0100] Step 406 involves determining the proportion of reactants that should be transferred to the reactor portion of the first reactor feed line compared to the second reactor feed line. For example, the reactor system may have a default operation where reactants are completely transferred via the second reactor feed line, which is delivered to the bottom of the reactor. To achieve a change in reactor conditions (e.g., temperature), it may be necessary to transfer a certain proportion of the reactor to the first reactor feed line, which is delivered to the top of the reactor (thus bypassing heat exchange occurring within the reactor tubes), and additional preheating may also be required to increase the reactor temperature. The controller can determine how much reactant must be transferred, for example, based on the volume percentage of the reactants, to achieve the desired process change quickly, stably, and safely.

[0101] Step 408 involves actuating one or more corresponding valve elements to transfer the desired amount of reactant to the first reactor feed line compared to the second reactor feed line. Depending on the type of valve element used at a location within the reactor section, a 10% volume transfer of reactant may require a 50% closure of the shut-off valve element on the second reactor feed line. All such calculations will be subject to various process constraints and conditions, including reactant composition, reactor type, catalyst type, heat exchanger efficiency, and / or others.

[0102] Step 5, 410, involves detecting changes in process conditions resulting from the transfer of a portion of the reactants to the first reactant feed line. Detection in step 5, 410, and any other related steps can be accomplished using suitable sensors, including thermocouples, pressure sensors, flow meters, or others. Sensors can be configured to communicate with a controller to indicate the current state of process conditions through the reactor system and associated equipment. For example, thermocouples or other suitable temperature sensors can be positioned at various locations within the reactor. For instance, thermocouples can be positioned at the top and bottom of the reactor, and at at least one location within the catalyst body near the catalyst, and at any one or more catalyst beds within the reactor body. Similarly, the temperatures of the reactor effluent lines, the combined reactant feed, the first and second reactor feed lines, the heat exchangers, and any other suitable lines or equipment can be obtained and monitored, and used to determine appropriate actuation of valve elements.

[0103] If the desired process conditions have not yet been achieved—as indicated by the detected changes—steps 406, 408, and 410 can be repeated once or more until the desired changes are achieved. It should be understood that any suitable process control scheme or strategy can be used, including feedback, feedforward, proportional, integral, derivative, proportional-integral, proportional-derivative, integral-derivative, model prediction, combinations thereof, or others, to determine appropriate process conditions by the controller based on the detected changes in process conditions, to determine the appropriate proportion of reactants to be transferred to the feed line of the first reactor, and to determine the degree of actuation of valve elements that should be directed to achieve the desired process conditions.

[0104] The controller may include a processor, memory, I / O interface and other suitable components for receiving signals from sensors, determining changes in process conditions, determining the appropriate proportion of reactants transferred to the feed line of the first reactor, and / or determining the degree of actuation of valve elements.

[0105] By providing a load-following reactor, related equipment, and operating method according to the disclosed embodiments, the problems of insufficient, inefficient, and suboptimal response to changing process conditions in the prior art are solved, particularly in the context of responding to changes in reactant flow rates and overcoming the thermal inertia of the reactor. The disclosed embodiments of the load-following reactor system, related equipment, and operating method provide a simplified, efficient, and improved manner for adjusting desired process conditions, such as reactor temperature, in response to changes in different process conditions (e.g., reactant flow rates). The load-following reactor, related equipment, and operating method advantageously reduce the time it takes for the reactor to reach thermal equilibrium, especially during changes in flow rates and conditions, which is common in load-following reactor systems.

[0106] It should be understood that not all objectives or advantages will necessarily be achieved under any embodiment of this disclosure. Those skilled in the art will recognize that load-following reactors, related facilities, and methods of operation may be embodied or implemented in a manner that achieves or optimizes one or more of the taught advantages without achieving other taught or suggested objectives or advantages.

[0107] Those skilled in the art will recognize the interchangeability of the various disclosed features. In addition to the variations described, other known equivalents of each feature can be mixed and matched by those of ordinary skill in the art to manufacture or use load-following reactors and related equipment in accordance with the principles of this disclosure. It will be understood by those skilled in the art that the described features are applicable to other types of chemicals and processes. Therefore, this disclosure and its embodiments, and variations thereof, are not limited to methanol synthesis processes or load-following applications, but can be used in any chemical or energy-related process.

[0108] While this disclosure describes certain exemplary embodiments and examples of load-following reactors, related equipment, and methods of operation thereof, those skilled in the art will understand that extensions from the embodiments specifically disclosed herein are possible to other alternative embodiments and / or uses of this disclosure, as well as their obvious modifications and equivalents. It is intended that this disclosure should not be limited to the embodiments specifically disclosed above.

Claims

1. A load-following reactor system, comprising: At least one reactor configured to carry out at least one chemical reaction; The structure is a reactant pipeline for transporting reactive materials; A first heat exchanger, wherein a first portion of the reaction stream is configured to reach the at least one reactor via the first heat exchanger and through a first feed line; At least one valve element configured to control the flow rate of a first portion of the reaction stream to the first feed line; and At least one second feed line is connected to the at least one reactor, and the remainder of the reaction stream is configured to pass through the second feed line; The load-following reactor system further includes multiple pipes extending through the main body of the reactor; The first heat exchanger is arranged outside the at least one reactor; Wherein, the first feed line is connected to the at least one reactor, such that a first portion of the reaction stream transported through the first feed line partially or completely bypasses the plurality of pipes; and The second feed line is connected to the at least one reactor such that the remainder of the reaction stream delivered through the second feed line flows upward through the plurality of pipes from the bottom to the top of the at least one reactor, and flows countercurrently relative to the flow direction of reactants, byproducts and products within the body of the at least one reactor.

2. The load-following reactor system according to claim 1, wherein, The first heat exchanger is configured to heat a first portion of the reaction stream.

3. The load-following reactor system according to claim 1, wherein, The first heat exchanger is thermally integrated with the effluent line of the at least one reactor.

4. The load-following reactor system according to claim 1, wherein, The at least one valve element includes a first valve and a second valve respectively arranged on the first feed line and at least one second feed line.

5. The load-following reactor system according to claim 1, wherein, It also includes a second heat exchanger arranged as a thermally integrated heat exchanger.

6. The load-following reactor system according to claim 5, wherein, The second heat exchanger is heated by the effluent line and transfers a portion of the heat from the effluent line to the reactant line.

7. The load-following reactor system according to claim 6, wherein, The second heat exchanger is arranged to be heated by the effluent line downstream of the first heat exchanger.

8. The load-following reactor system according to claim 1, wherein, The reaction stream includes a fresh CO2 feed and a fresh H2 feed.

9. The load-following reactor system according to claim 1, wherein, The first feed line is connected to the top of the at least one reactor.

10. The load-following reactor system according to claim 1, wherein, The at least one reactor is a methanol synthesis reactor containing a methanol synthesis catalyst or catalyst bed, and the plurality of tubes extend through the catalyst or catalyst bed.

11. The load-following reactor system of claim 1, further comprising a controller configured to receive a temperature signal from the at least one reactor and at least one flow signal from the reaction stream, and to control the actuation of the at least one valve element based on the received temperature signal.

12. A method of operating a load-following reactor system according to claim 1, the method comprising the steps of: Detect one or more process conditions in the at least one reactor; Determine the detected changes in one or more process conditions; Based on the determined changes in process conditions, determine the proportion of the reaction stream to be transferred to the first feed line; and The at least one valve element is actuated according to the determined proportion of the reaction stream to be transferred.

13. The method of claim 12, further comprising providing a reaction stream to the reactant pipeline, wherein the reaction stream comprises a fresh CO2 feed and a fresh H2 feed, and performing methanol synthesis in the at least one reactor.

14. The method according to claim 12, wherein, Actuating the at least one valve element includes actuating a first valve and a second valve respectively arranged on the first feed line and at least one second feed line.

15. The method according to claim 12, wherein, The plurality of tubes define the preheating section of the reactor.

16. The method according to claim 15, wherein, The first feed line is connected to the top of the at least one reactor.

17. The method of claim 12, further comprising keeping the first heat exchanger warm regardless of how the valve element operates.

18. A load-following reactor system, comprising: At least one reactor configured to carry out at least one chemical reaction; The structure is a reactant pipeline for transporting reactive materials; A first heat exchanger, wherein a first portion of the reaction stream is configured to reach the at least one reactor via the first heat exchanger and by means of a first feed line; At least one valve element configured to control the flow rate of a first portion of the reaction stream to the first feed line; and At least one second feed line is connected to the at least one reactor, and the remainder of the reaction stream is configured to pass through the second feed line; The load-following reactor system further includes multiple pipes extending through the main body of the reactor; The first heat exchanger is arranged outside the at least one reactor; Wherein, the first feed line is connected to the at least one reactor, such that a first portion of the reaction stream transported through the first feed line partially or completely bypasses the plurality of pipes; and The second feed line is connected to the at least one reactor such that the remainder of the reaction stream delivered through the second feed line flows through the plurality of pipes and the top of the at least one reactor, wherein the plurality of pipes define a preheating section of the reactor, and wherein byproducts and products generated in the at least one reactor flow downward toward the outlet of the at least one reactor.

19. The load-following reactor system according to claim 18, wherein, The at least one valve element is controlled according to the temperature of the reactor.

20. The load-following reactor system of claim 19, further comprising a controller configured to receive at least one temperature signal from the at least one reactor and at least one flow signal from the reaction stream.

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