Methanol synthesis reactor

Abstract

An improved reactor includes a shell and at least one reactor internal component. The reactor internal component includes a tube bundle including a plurality of tubes connected by at least one tube support plate, the tube support plate including at least one radial strut and at least one bracket configured to secure to at least one tube of the tube bundle. The tubes are arranged in concentric bands about a longitudinal axis of the reactor. The reactor can also include a gas inlet plate, a catalyst support plate, and a top plate.

Description

Technical Field

[0001] This disclosure relates to reactors, and more particularly to reactors used for methanol synthesis. Background Technology

[0002] Global climate change has been recognized as "the most pressing environmental challenge of our time." NASA states, "The scientific evidence for a warming climate system is irrefutable." Climate change is caused by the warming effects of greenhouse gases such as water vapor, nitrous oxide, methane, and carbon dioxide. Carbon dioxide emissions are the primary culprit, as the concentration of carbon dioxide in the global atmosphere has increased by one-third since the beginning of the Industrial Revolution. Carbon dioxide emissions mainly originate from human activities, such as the consumption of fossil fuels, whose byproducts are released into the atmosphere.

[0003] Through exploration, chemical energy storage has emerged as a solution to the inherent intermittency and unpredictability of renewable energy sources such as wind and solar power. Due to the intermittency of wind and solar energy, grids and power companies must rely on fossil fuel-based energy sources to meet basic electricity demands. Sudden bursts of wind and solar power are difficult to integrate into the grid due to the difficulty in rapidly scaling down and up these fossil fuel-based energy sources (such as coal-fired power plants). Since many renewable energy sources are difficult to scale up to replace traditional fossil fuel energy, high-density energy storage of renewable energy is crucial for addressing climate change, enabling renewable energy to be stored and used when the grid can accommodate it.

[0004] To date, existing energy storage methods, including thermal energy storage, compressed air energy storage, hydrogen energy storage, pumped hydro storage, and large-scale batteries, have proven to be very expensive and / or difficult to scale. Chemical storage of renewable energy in the form of hydrogen produced by water electrolysis, for use in combustion, fuel cell consumption, or chemical synthesis (such as methanol synthesis), is a promising approach that can provide sufficiently dense and stable renewable energy storage that can be used on demand, enabling renewable energy to continuously rather than intermittently supply energy needs.

[0005] The reactors used to synthesize methanol from syngas are typically limited to boiling water reactors (BWRs) because typical reaction suites are very hot, including large amounts of CO. BWRs are complex and expensive equipment, but they are often necessary to reduce the heat generated during the exothermic process of producing methanol from syngas, thereby protecting the reaction products, the reactor, and the catalyst.

[0006] Shell-and-tube reactors used for catalytic and / or exothermic reactions (such as the synthesis of methanol from carbon dioxide and hydrogen using suitable catalysts, such as copper- and zinc-oxide-based catalysts or other suitable catalysts) must undergo regular maintenance, such as loading and / or removing and refilling the catalyst, descaling the reactor shell, servicing various components, or other operations. A balance needs to be struck between the ability to access the reactor interior for catalyst loading, maintenance, and other purposes and the ability to keep the tubes bundled together.

[0007] Existing shell-and-tube reactor designs are difficult to scale up or down to meet the specific needs of a facility, such as required throughput. The facility's throughput may vary over time due to debottlenecking operations, potentially increasing the reactor's throughput requirements. Scaling up a reactor to eliminate a facility's bottleneck is a difficult, expensive, and time-consuming undertaking, often requiring modification or redesign of the entire reactor, including its internal structure.

[0008] This can require significant design and engineering effort, as engineers essentially have to do "disruptive work" when scaling up designs, considering tube arrangement and cross-sectional area, shell size and construction, catalyst bed volume and cross-sectional area, and other factors. Existing shell-and-tube reactor designs and suppliers struggle to effectively adapt reactor designs to changing requirements. Poor reactor design can lead to uneven distribution of catalyst, reactants, and heat, damaging catalyst and / or reactor components and reducing reaction efficiency. In some cases, runaway exothermic reactions can cause catastrophic reactor failure.

[0009] Furthermore, properly manufacturing and scaling the feed pipe within and / or for the reactor is challenging. Improperly designed, arranged, and / or manufactured feed pipes often lead to blockages, eddies, and non-uniform regions of reactants within the reactor, adversely reducing reactor efficiency and yield, and potentially creating hot spots. Hot spots in exothermic reactions are particularly dangerous and detrimental to both the reactor and the catalyst.

[0010] Another problem in reactor design is the difficulty in measuring the internal temperature of the reactor at one or more desired locations. Without knowing the temperature profiles inside the reactor, especially those corresponding to different stages of the reaction and / or different reaction conditions at different locations along the reactor body, it is difficult to properly control the process, including the reactor, particularly in high-risk applications such as exothermic reactions.

[0011] However, thermocouple joints, including gasket seats, can deteriorate over time, leading to leaks. While such leaks can be repaired, doing so requires decommissioning the catalyst and replacing the gasket seats. This involves costly, potentially hazardous, and time-consuming shutdowns, catalyst decommissioning, and restarts, each with significant costs, including substantial opportunity costs. Given that the expected lifespan of a catalyst is typically between three and five years, such repairs constitute a very expensive disruption to facility operation. Furthermore, in high-pressure and / or high-temperature reactions involving hydrogen, the risk of leaks originating from flange joints is particularly high, including external leaks of hydrogen or other reactants / products, as well as internal leaks of catalyst poisons, namely oxygen.

[0012] Therefore, existing reactor designs, which include multiple thermocouple wells to provide thermocouples at different heights within the reactor body, are prone to operational interruptions due to thermocouple joint leaks. Reactor designs that omit these thermocouple wells to avoid interruptions lack the necessary reactor condition data for proper reaction control. Furthermore, existing thermocouple well configurations in reactors insert thermocouples laterally (e.g., radially) into the reactor body. This adversely leads to temperature readings in large reactors approaching shell conditions, further hindering reactor design expansion. Reactor designs also struggle to allow thermocouple insertion within the reactor body without damaging the thermocouples in the presence of a catalyst.

[0013] Existing reactor designs may include one or more nozzles for unloading spent catalyst, for example, from the bottom of the reactor body. The design of catalyst unloading nozzles in existing reactors is not suitable for efficient and rapid catalyst removal, therefore operators must scrape the catalyst out of the reactor body.

[0014] Some shell-and-tube reactors and other types of reactors may include an inlet nozzle from which reactant gases are drawn out through a tube extending through the center of the reactor body. This tube may be drilled to accommodate one or more feed tubes, each of which may be bent to connect to the inlet nozzle, and then the reactants are conveyed upwards through the reactor body. Such reactor configurations are not suitable for scaling up, for example, to hundreds of tubes, because precise and tube-specific adjustments must be made to connect the tubes to each feed tube.

[0015] In some reactor configurations, the inlet pipe is further used to support the feed pipe at different heights within the reactor body, with one or more flat strips welded and extended between the inlet pipe and one or more feed pipes. This construction is very time-consuming, especially for manufacturing, assembling, and maintaining large reactors, complicating the task of scaling up reactor designs to meet facility requirements. Furthermore, the inlet pipe disadvantageously occupies a significant cross-sectional area that could otherwise be used for catalyst. While tie rods have been considered for supporting the feed pipe in shell-and-tube reactors, such support would occupy catalyst space and create obstacles during catalyst loading and unloading.

[0016] As stated above, there is a need for an improved reactor that is configured to maintain the reactor interior and manage the catalyst, increase or decrease the reactor output according to the facility’s production needs, improve the measurement of reactor conditions without affecting the reactor’s integrity and maintainability, effectively remove spent catalyst, improve manufacturing, and overcome the challenges of building shell-and-tube reactors. Summary of the Invention

[0017] Embodiments of the reactor according to this disclosure advantageously address the shortcomings of existing reactor designs by providing scalable and / or constructed reactors that improve accessibility and maintainability, particularly the reactor interior. Embodiments of the reactor can be constructed to facilitate access to the reactor interior without sacrificing the strength and robustness of internal components, such as reactor tube bundles consisting of one or more tubes and one or more support structures, thereby keeping the tube bundles intact and undamaged.

[0018] Embodiments of the reactor further include tube arrangements configured to be easily scaled up or down to suit the needs of a particular facility. In existing reactor designs, tubes cannot be easily added to or removed from the tube bundle according to the shape of the reactor shell during reactor construction without significant redesign work. Embodiments of this disclosure advantageously allow for the modular arrangement of circumferential bands or other arrangements of tubes according to the required throughput of the reactor and associated facilities. In some embodiments, the tube arrangements may define regular and / or repetitive patterns that can be easily added to and / or removed from existing tube bundle designs during reactor design. This has the advantage of making debottlenecking operations or other design work easier and less costly from a manufacturing perspective.

[0019] The arrangement of the tube bundles further facilitates the distribution of heat and reactants throughout the reactor, particularly through the catalyst bed, without disrupting the catalyst loading, which typically occurs when operators load or dump catalyst particles into the reactor from the open top. The reactor and tube bundle arrangements of embodiments of the invention advantageously provide a modular design for improved constructability while maintaining ideal characteristics regarding heat and reactant distribution, and also ensuring a uniform distribution of catalyst particles within the reactor.

[0020] The tube bundles according to reactor embodiments of this disclosure are further configured to provide improved structural support to one or more tubes to increase the stability of the reactor during construction, transport, and installation, as well as during operation. In some embodiments, one or more structural supports and / or one or more tubes are provided with increased thickness to ensure structural support at desired locations within the tube bundle.

[0021] In some embodiments, the reactor and its components are configured to facilitate accessibility for maintenance of critical components. One or more plates configured to support the tube bundle can be modular, allowing operators easy loading and unloading of catalysts or access to components inside the reactor, whereas in existing reactors, components such as support plates are welded to the inner surface of the reactor shell, prohibiting access to components inside the reactor.

[0022] By providing improved inlet nozzles and distribution mechanisms configured to guide reactants into a tube bundle arranged within the reactor, embodiments of the reactor address the problem that existing reactor designs are unsuitable for providing adequate flow and reactant distribution within the reactor and catalyst bed, and thus for adequate heat distribution. In some embodiments, the inlet nozzles are positioned near the gas inlet plate, with their flow direction opposite to that of the individual tubes in the tube bundle. A second inlet nozzle may be provided at the bottom of the reactor, which may be configured to uniformly distribute fluid into the tubes of the tube bundle. In some embodiments, one or more catalyst unloading nozzles are provided in an improved configuration for purging catalyst, the unloading nozzles being configured to have a downward angle.

[0023] The arrangement of tube bundles and tubes can improve the cross-sectional area of ​​the tubes relative to the cross-sectional area of ​​the catalyst, so as to achieve uniform heat and flow distribution without interfering with the structure and modular features of the tube bundles.

[0024] Examples of reactors are further configured to reduce clogging, eddies, and / or non-uniform regions of reactants and associated hot spots within the reactor body by providing improved distribution of catalyst, reactor internal components, and reactants during the reaction process.

[0025] The reactor embodiments disclosed herein further address shortcomings in existing reactor designs regarding process control and temperature measurement. In some embodiments, the reactor is configured to provide one or more thermocouple wells configured to receive one or more respective thermocouples. The thermocouples may be configured to measure the temperature inside the reactor at multiple locations using individual thermocouple wells arranged axially or longitudinally relative to the reactor body.

[0026] An exemplary embodiment of this disclosure relates to a reactor including a shell defining an internal space, at least one inlet nozzle, and a tube bundle including one or more tubes.

[0027] In one embodiment, the reactor further includes a catalyst support plate.

[0028] In one embodiment, the reactor further includes at least one tube support plate.

[0029] In one embodiment, the reactor further includes a gas inlet plate.

[0030] In one embodiment, the reactor also includes a top plate.

[0031] In one embodiment, the reactor further includes a top plate and a tube support plate.

[0032] In one embodiment, the shell is configured to receive at least one catalyst.

[0033] In one embodiment, at least one catalyst is a solid catalyst. Such catalyst may include spheres of a first diameter.

[0034] In one embodiment, the solid catalyst comprises a sphere of a second diameter.

[0035] In one embodiment, the shell is configured to receive at least one solid catalyst. This solid catalyst may include at least one shape selected from particulate, cyclic, flake, or spherical forms.

[0036] In one embodiment, the catalyst support plate is configured to support a solid catalyst at a certain height.

[0037] In one embodiment, the catalyst support defines one or more openings.

[0038] In one embodiment, one or more openings include a plurality of first-size openings and a plurality of second-size openings that extend through at least a portion of the thickness of the catalyst support plate.

[0039] In one embodiment, the first dimension corresponds to the circumference of at least one tube in the tube bundle.

[0040] In one embodiment, the second dimension is smaller than the first dimension.

[0041] In one embodiment, the second dimension is a function of the thickness of the catalyst support plate.

[0042] In one embodiment, the opening of the first size is defined as passing through the catalyst support plate in the manner of the arrangement of multiple tubes.

[0043] In one embodiment, the gas inlet plate includes a plurality of openings defined to extend through the thickness of the gas inlet plate.

[0044] In one embodiment, the plurality of openings are defined as circular openings passing through the gas inlet plate according to the arrangement of the plurality of tubes.

[0045] In one embodiment, the gas inlet plate further includes a second plurality of openings defined through the thickness of the gas inlet plate, the second plurality of openings having a different size and / or shape than the plurality of circular openings.

[0046] In one embodiment, the housing defines an outlet nozzle.

[0047] In one embodiment, the outlet nozzle is located on the side of the housing.

[0048] In one embodiment, the inlet nozzle is located near the bottom of the housing.

[0049] In one embodiment, the inlet nozzle is arranged transversely to the flow direction through the housing.

[0050] In one embodiment, the inlet nozzle is substantially parallel to the flow direction through the housing.

[0051] In one embodiment, the gas inlet plate is arranged near the inlet nozzle.

[0052] In one embodiment, the at least one tube support plate includes at least one circumferential band.

[0053] In one embodiment, the at least one circumferential band includes at least one support configured to extend around a portion of the tube bundle.

[0054] In one embodiment, the at least one support extends around the entire tube.

[0055] In one embodiment, the housing defines an initiation nozzle configured to provide heated fluid.

[0056] In one embodiment, the reactor further includes at least one catalyst unloading nozzle.

[0057] In one embodiment, the reactor also includes a handhole.

[0058] In one embodiment, at least one tube support plate defines a plurality of concentric circumferential bands.

[0059] In one embodiment, the tube bundle includes at least one tube of a first size and at least one tube of a second size.

[0060] In one embodiment, the inlet nozzle is positioned below the gas inlet plate.

[0061] In one embodiment, the housing defines an outlet nozzle, wherein the outlet nozzle is disposed below the catalyst support plate.

[0062] In one embodiment, catalysts of a first size (e.g., diameter) (e.g., spheres) and catalysts of a second size (e.g., diameter) (e.g., spheres) are disposed in discrete corresponding layers near the catalyst support plate.

[0063] In one embodiment, the housing is configured to receive at least one solid catalyst, wherein the catalyst has a first height within the housing in an unreduced state and a second height within the housing in a reduced state (e.g., due to sedimentation that may occur during operation).

[0064] In one embodiment, the second height is lower than the first height.

[0065] In one embodiment, at least one tubular support plate defines at least one radial strut connected to at least one of a plurality of circumferential bands.

[0066] In one embodiment, at least one radial strut is connected to at least one of the circumferential belt and the external support belt.

[0067] In one embodiment, the innermost circumferential band of at least one tube support plate includes a plurality of (e.g., 6) supports, each configured to correspond to a ring consisting of the same number of innermost tubes of the first size.

[0068] In one embodiment, the second circumferential band of at least one tube support plate includes the same number or more (e.g., 10) of supports as the first circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle located in the second concentric band or ring of the tube. Such a tube may have a first size.

[0069] In one embodiment, the third circumferential band of at least one tube support plate includes the same number or more (e.g., 14) of supports as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle located in the third concentric band or ring of the tube. Such a tube may have a second size.

[0070] In one embodiment, at least one circumferential band of the tube support plate includes the same number or more (e.g., 18) of supports as the preceding circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle located in the fourth concentric band or ring of the tube. Such a tube may be of a first size.

[0071] In one embodiment, the fifth circumferential band of at least one tube support plate includes the same number (e.g., 22) of supports as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) in the fifth concentric band or ring of the tube bundle. Such a tube may be of a first size.

[0072] In one embodiment, the sixth circumferential band of at least one tube support plate includes the same number or more (e.g., 26) of supports as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) in the sixth concentric band or ring of the tube bundle. Such a tube may be of a first size.

[0073] In one embodiment, the seventh circumferential band of at least one tube support plate includes the same number or more (e.g., 30) of supports as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) in the seventh concentric band or ring of the tube bundle. Such a tube may be of a second size.

[0074] In one embodiment, the eighth circumferential band of at least one tube support plate includes the same number or more (e.g., 34) of supports as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) in the eighth concentric band or ring of the tube bundle. Such tubes may be of a first size.

[0075] In one embodiment, the ninth circumferential band of at least one tube support plate includes the same number or more (e.g., 36) of supports as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) in the ninth concentric band or ring of the tube bundle. Such tubes may be of a first size.

[0076] In one embodiment, the tenth circumferential band of at least one tube support plate includes the same number (e.g., 42) of supports as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) in the tenth concentric band or ring of the tube bundle. Such tubes may be of a first size.

[0077] In one embodiment, the eleventh circumferential band of at least one tube support plate includes the same number (e.g., 46) of supports as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) in the eleventh concentric band or ring of the tube bundle. Such a tube may be of a second size.

[0078] In one embodiment, the twelfth circumferential band of at least one tube support plate includes the same number (e.g., 50) of supports as the preceding circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle located in the twelfth concentric band or ring of the tube. Such tubes may be of a first size.

[0079] In one embodiment, the thirteenth circumferential band of at least one tube support plate includes the same number (e.g., 54) of supports as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle located in the thirteenth concentric band or ring of the tube. Such tube may be of a first size.

[0080] In one embodiment, the 14th circumferential band of at least one tube support plate includes the same or more supports as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) in the 14th concentric band or ring of the tube bundle. Such a tube may be of a second size.

[0081] Clearly, any number of circumferential bands can be provided.

[0082] In one embodiment, any circumferential band of at least one tube support plate further includes a support corresponding to at least one thermocouple insert tube configured to receive a temperature measuring device. Such a thermocouple insert tube may have dimensions similar to the tubes in the tube bundle (e.g., tubes of a first or second size).

[0083] In one embodiment, at least four tube support plates are arranged longitudinally along the tube bundle.

[0084] In one embodiment, at least one tube support plate is arranged longitudinally along the tube bundle, wherein the circumferential band of the at least one tube support plate further includes a support corresponding to at least one thermocouple insertion tube, wherein the at least one thermocouple insertion tube is configured to receive a temperature measuring device.

[0085] In one embodiment, the temperature measuring device is configured to obtain the temperature at multiple longitudinal locations within the reactor.

[0086] In one embodiment, the temperature measuring device is configured to obtain the temperature at multiple locations (e.g., at least eight different locations) along the longitudinal direction of the reactor.

[0087] In one embodiment, the housing defines at least one flange to facilitate connection and separation of the upper portion of the housing from the body portion of the housing.

[0088] In one embodiment, the housing is configured to be attached to a skirt at the bottom portion of the housing.

[0089] In one embodiment, the skirt defines an opening configured to receive an inlet valve core.

[0090] In one embodiment, at least one tube support plate defines at least one radial strut connected to at least one of a plurality of circumferential bands of the tube support plate, wherein at least one radial strut of the at least one tube support plate is axially aligned with at least one radial strut of another tube support plate.

[0091] In one embodiment, at least one radial strut of at least one tube support plate is axially offset relative to at least one radial strut of an adjacent tube support plate.

[0092] In one embodiment, at least one tube support plate defines a plurality of radial struts arranged symmetrically about the longitudinal axis of the reactor.

[0093] In one embodiment, at least one tube support plate defines at least one radial strut connected to at least one of a plurality of circumferential bands of the tube support plate, wherein at least one circumferential band of the at least one tube support plate is detachably fixed to the at least one radial strut.

[0094] In one embodiment, at least one tube of the tube bundle defines a uniform thickness in the longitudinal direction within the reactor.

[0095] In one embodiment, at least one tube of the tube bundle defines a longitudinally decreasing thickness within the reactor.

[0096] In one embodiment, at least one tube of the tube bundle is configured to facilitate greater heat transfer near the bottom of the reactor relative to the top of the reactor.

[0097] Any of the features mentioned above or other features described herein may be used in combination with each other, individually, or in combination with other features.

[0098] Other methods, embodiments, and variations of this system will be described in more detail in the following discussion. Attached Figure Description

[0099] These and other features, aspects and advantages of the invention will become clear and better understood from the following description, the appended claims and the accompanying drawings.

[0100] Figure 1AThis is a perspective view of a reactor according to an embodiment of the present disclosure.

[0101] Figure 1B It is based on Figure 1A A perspective view of the reactor of the illustrated embodiment after it has been rotated by an angle.

[0102] Figure 2 It is based on Figure 1A A plan view of the reactor in the illustrated embodiment.

[0103] Figure 3 yes Figure 1A The side sectional view along line 1A-1A of the illustrated embodiment shows the reactor and its internal components.

[0104] Figure 4 yes Figure 1A The side sectional view along line 1A-1A of the illustrated embodiment shows the reactor, catalyst bed, and catalyst support layer.

[0105] Figure 5A yes Figure 1A An enlarged side sectional view of part IV of the reactor in the illustrated embodiment.

[0106] Figure 5B yes Figure 1A An enlarged side sectional view of part III of the reactor in the illustrated embodiment.

[0107] Figure 6 It is used according to Figure 1A A perspective view of the tube bundle of the reactor in the illustrated embodiment.

[0108] Figure 7 yes Figure 6 A side view of the tube bundle in the illustrated embodiment.

[0109] Figure 8 It is based on Figure 6 A perspective view of the tube bundle and tube support plate of the illustrated embodiment.

[0110] Figure 9 It is based on Figure 1A A plan view of the feed pipe support plate at the top of the reactor in the illustrated embodiment.

[0111] Figure 10A It is based on Figure 6 A plan view of the tube support plate in the embodiment shown.

[0112] Figure 10B This is a plan view of the tube support plate according to another embodiment.

[0113] Figure 11 It is based on Figure 1A A plan view of the gas inlet plate of the reactor in the illustrated embodiment.

[0114] Figure 12 It is based on Figure 1A A plan view of the catalyst support plate of the reactor in the illustrated embodiment.

[0115] Figure 13 This is a magnified plan view of part XII of the catalyst support plate.

[0116] Figure 14 It is based on Figure 1A An exploded perspective view of the top plate and reactor in the illustrated embodiment.

[0117] Figure 15 yes Figure 14 A plan view of the top plate in the illustrated embodiment.

[0118] Figure 16 It is used according to Figure 1A An enlarged exploded perspective view of part XIV of the top plate of the reactor in the illustrated embodiment.

[0119] Figure 17 It is used according to Figure 1A The side section view of the nozzle limiting plate of the reactor in the illustrated embodiment along line 16A-16A.

[0120] Figure 18 It is based on Figure 17 A view of the limiting plate and nozzle in the illustrated embodiment.

[0121] Figure 19 It is based on Figure 17 A perspective view of the limiting plate and nozzle in the illustrated embodiment.

[0122] Figure 20 This is a side sectional view of the reactor, catalyst bed, and thermocouple insertion tube according to another embodiment. Detailed Implementation

[0123] Various embodiments of the invention will be better understood through the following description and accompanying drawings, in which similar reference numerals indicate similar markings.

[0124] While various modifications and alternative structures may be made to this disclosure, certain exemplary 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 structures, compositions, and equivalents that fall within the spirit and scope of this disclosure and are defined by the appended claims.

[0125] It should be understood that unless a term in this patent is defined to have the meaning described, there is no intention to limit the meaning of the term beyond its simple or ordinary meaning, whether explicit or indirect.

[0126] Let's take a look Figure 1A The image shows a reactor 100 according to an embodiment of the present disclosure. The reactor 100 includes a defined internal space 103 (see [link to documentation]). Figure 4 The reactor 100 includes a housing 102 and at least one inlet nozzle 120. The reactor 100 is configured to accommodate and cooperate with at least one internal reactor component, such as a tube bundle 130 consisting of one or more tubes 131. Figure 3 The reactor 100 extends longitudinally from the top 105 to the bottom 107 around the axis 1A-1A, and can define a generally cylindrical shape.

[0127] The inlet nozzle 120 is positioned approximately near the bottom end 107 so that one or more reactants can enter through the inlet nozzle 120 and then move upward in direction F1 through one or more tubes 131 through the internal space 103 of the reactor 100. Figure 4 Then, near the upper end 105, it exits from pipe 131, turning downwards along direction F2 to outlet nozzle 124, which defines the corresponding flange 125. As the reactants move upwards through one or more pipes 131, the reactants react with the catalyst and along direction F2 ( Figure 4 The reactants and products moving downwards exchange heat.

[0128] In exothermic reactions such as methanol synthesis, the reactants advantageously absorb the heat generated by the reaction within tube 131, thus preheating the reactants before they are conveyed to catalyst bed 140. This also advantageously mitigates the formation of catalyst hotspots, as well as associated catalyst sintering and product degradation. It also reduces the likelihood of runaway reactions, as the reactants serve as the heat exchange medium for removing heat from the catalyst bed. Due to the distribution of tubes 131, the heat exchange mechanism formed by the reactants is far more efficient than, for example, a cooling water jacket surrounding reactor 100.

[0129] In addition to the inlet nozzle 120 and the outlet nozzle 124, the reactor 100 also defines one or more catalyst unloading nozzles 116, and / or one or more handholes 118 through which access to the internal space 103 is provided. The one or more catalyst unloading nozzles 116 may be tilted downwards to facilitate gravity-based removal of the catalyst from the catalyst bed 140, for example, during the removal of spent catalyst and refilling. The one or more handholes 118 facilitate maintenance by allowing technicians to insert their hands, tools, or instruments into the internal space 103 near the catalyst support plate 154, the catalyst bed 140, or any other suitable location.

[0130] like Figure 1A and 1BAs shown, reactor 100 defines a start-up nozzle 110, configured to provide a heating fluid. During start-up operation, when the reaction has not yet reached steady-state operation, the reactants may not receive the necessary amount of preheating as they move in direction F1 within tube bundle 130. The start-up nozzle 110 can receive a heating fluid, such as an inert gas, like heated nitrogen, which can pass through the internal space 103 and provide sufficient enthalpy to reach steady-state operation without adversely affecting the reaction yield.

[0131] The housing 102 may also define at least one thermocouple port 106. Each thermocouple port 106 facilitates the insertion of a temperature measuring device into the reactor 100, and in some embodiments, into the tube bundle 130 in an axial or longitudinal direction. By positioning the thermocouple port 106 at the top 105 of the reactor 100, a single temperature measuring device (such as a thermocouple) can be inserted through this port, enabling temperature measurement at multiple locations. In some embodiments, the temperature measuring device may extend elongatedly and include multiple measuring elements, such as thermocouples, thereon at predetermined distances, thereby allowing measurement of reactor conditions at each of the predetermined distances to improve control of the reaction.

[0132] Although Figure 1A and 1B The diagram shows two thermocouple ports 106 on opposite sides of the start-up nozzle 110, but it will be understood that more or fewer thermocouple ports 106 may be provided at any suitable location. By providing temperature measurement devices through the thermocouple ports 106, reactor 100 advantageously allows for the measurement of reactor conditions at different height positions of the reactor while minimizing the number of thermocouple connections, thereby facilitating improved process control and yield while minimizing the risk of leakage (whether into or out of the housing 102). The location of the thermocouple ports 106 also allows for sampling of reactor conditions at desired radial locations within reactor 100, regardless of the size of reactor 100, contrary to existing reactor designs where thermocouples are inserted radially, resulting in large reactors being sampled too close to the housing.

[0133] Let's take a look Figure 4 The housing 102 may define an inlet nozzle 120 having a flange 121 disposed a distance below the gas inlet plate 156, both of which are located near the bottom end 107 of the reactor 100. The inlet nozzle 120 may be arranged laterally relative to the longitudinal extension direction of the reactor 100 such that when reactants enter through the inlet nozzle 120 in the flow direction F4, the reactants change direction and enter one or more tubes 131 of the tube bundle 130 in the direction F1 through the gas inlet plate 156.

[0134] The inlet nozzle 120 can be arranged as shown to optimize the distance between the inlet nozzle 120 and the bottom of the tube bundle 130, and to ensure uniform distribution of reactants into the tube 131, thereby avoiding eddies that could lead to blockages, hot spots, and uneven flow. The flange 121 can be configured to facilitate connection of the reactant feed line to the inlet nozzle 120. Although the inlet nozzle 120 has been shown and described, it will be understood that the distance between the inlet nozzle 120 and the bottom of the tube bundle 130 can be set larger or smaller depending on the circumstances.

[0135] As an addition or alternative, housing 102 also defines a secondary inlet nozzle 132 having a corresponding flange 133, such as Figure 5A As shown. Flange 133 may be configured to facilitate connection of the reactant feed line to nozzle 132. Secondary inlet nozzle 132 is configured to deliver reactants perpendicularly in direction F3, which may correspond to or be parallel to the upward flow direction F1 through pipe 131. Reactor housing 102 may be secured by skirt 108, which may define an opening 122 through its thickness, configured to receive inlet valve core 135 connected to secondary inlet nozzle 132.

[0136] The skirt 108 may be cylindrical and extend downward from its bottom 107, substantially coexisting with the reactor shell 102. The skirt 108 may define a ring 109 for securing the reactor 100 and the skirt 108. The inlet valve core 135 may be arcuate to allow reactants to be fed into the reactor 100 in a flow direction substantially transverse to the flow direction F3, for example, in a direction substantially parallel to the direction F4 of the inlet nozzle 120. The inlet nozzle 120 and the secondary inlet nozzle 132 may be configured to operate simultaneously or independently. While skirts have been shown and described, any suitable support may be used, and this disclosure is not limited to the use of skirts.

[0137] In some embodiments, a diverter 137 is detachably disposed within the secondary inlet nozzle 132 or housing 102 to guide the flow direction of the reactants when using the secondary inlet nozzle 132. The diverter 137 may be shaped to distribute a portion of the reactant flow radially outward from the secondary inlet nozzle 132, thereby uniformly distributing the flow between a central tube (which is substantially aligned with the secondary inlet nozzle 132) and an outer tube. While the diverter 137 has been shown and described, it will be understood that any suitable structure, configuration, or arrangement may be used. In some embodiments, the diverter 137 defines a plurality of openings and / or protrusions configured to distribute the reactant flow entering through the nozzle 132.

[0138] Let's take a look Figure 5BThe reactor 100 may also include a dome-shaped head 104, which is removable from the housing 102 and releasably connected to flanges 112, 114, which may include any suitable construction for connecting the dome-shaped head 104 and the housing 102, such as boreholes and corresponding fasteners. The dome-shaped head 104 may define a space 113 above the top of the tube bundle 130. This space 113 provides a space for preheated reactants to be mixed and recirculated downward through the catalyst bed 140. As previously mentioned, the nozzle 110 may be defined by the thickness of the dome-shaped head 104 to allow the introduction of a heating medium during start-up operation.

[0139] While a dome-shaped head that can be releasably secured to the outer shell has been shown and described, it is understood that this disclosure is not limited thereto, and a fixed head (e.g., including flanged manholes) may be used alternatively for reactors of any size.

[0140] Thermocouple port 106 may be aligned with a respective thermocouple insert tube 126, which may extend a distance above the top of tube bundle 130. Thermocouple port 106 may extend through part or all of the thickness of dome head 104 to allow access to reactor interior 103. Thermocouple port 106 may facilitate access to reactor interior 103 in any suitable manner, for example by defining an opening of a certain size configured flush with the surface of the temperature measuring device, thereby maintaining pressure within reactor interior 103 by operation with gasket sealing (or a combination thereof, or any other suitable manner). Any suitable manner may be used. By extending a distance above the top of tube bundle 130, thermocouple insert tube 126 is configured to be more easily identifiable when thermocouples are installed, especially when access is restricted due to the dome head 104 being installed. Thermocouple insert tube 126 may extend substantially parallel to or aligned with feed tube 131 along the length of reactor 100.

[0141] The reactor 100 may also include one or more of the following: a catalyst support plate 154, at least one tube support plate 162, 163, 164, 165, a gas inlet plate 156, a top feed pipe support plate 150, and / or a top plate 190. These arrangements advantageously facilitate securing the tube bundle 130 within the housing 102 while allowing access to the reactor interior 103 when necessary for maintenance or other purposes. The gas inlet plate 156 and the catalyst support plate 154 may advantageously be welded to the inner surface of the housing 102 to secure the tube bundle 130 therein.

[0142] The tubes 131 of the tube bundle 130 may be welded to the gas inlet plate 156, the top feed pipe support plate 150, and / or at least one pipe support plate 162, 163, 164, 165. In some embodiments, only the gas inlet plate 156 is fixed to the inner surface of the reactor housing 102 by welding or otherwise, while the top feed pipe support plate 150 and at least one pipe support plate 162, 163, 164, 165 are not fixed to accommodate the thermal expansion of the tubes 131.

[0143] Let's take a look Figure 4 The catalyst bed 140 may include one or more stages of catalyst, such as a solid catalyst. The catalyst bed 140 may also additionally or alternatively include one or more inert sections 142, 144, which may include supporting ceramic balls of a first diameter, for example 1-30 mm, more specifically 5-20 mm, or 9 mm in some embodiments. The catalyst bed 140 may also include supporting ceramic balls of a second diameter, for example 1-30 mm, more specifically 10-25 mm, or 19 mm in some embodiments. The catalyst bed 140 may define different sections 142, 144, which correspond to essentially only including ceramic balls of a single size.

[0144] For example, in the described embodiments, portion 142 comprises essentially only spheres with a diameter of 9 mm, while portion 144 comprises only spheres with a diameter of 19 mm. Portions 142 and 144 may have any suitable height within reactor 100, for example, 5-500 mm, more specifically 100-300 mm, or in some embodiments, each portion 142 and 144 may have a height of 200 mm. Portions 142 and 144 may have the same height or different heights. Catalyst bed 140 may additionally or alternatively comprise a solid catalyst in a shape including at least one of granular, annular, flake, or spherical forms. Portions 142 and 144 may be disposed near (e.g., above or directly above) catalyst support plate 154 and below portion 141, which comprises essentially only solid catalyst in a shape and / or size different from the supporting ceramic spheres of portions 142 and 144.

[0145] The supporting ceramic spheres 142, 144 advantageously support the weight of the catalyst in the catalyst bed while promoting efficient and uniform flow distribution. By providing different first spheres 142 and second spheres 144, the flow of reactants, products, and byproducts through the reactor interior 103 to the outlet nozzle 124 is improved because the gas is allowed to flow between the catalyst particles in the catalyst bed 140, between the smaller first-diameter supporting ceramic spheres in the first sphere 142, and finally between the larger second-diameter supporting ceramic spheres in the second sphere 144, before flowing through the catalyst support plate 154. Advantageously, the supporting ceramic spheres are inert and constructed to resist thermal shock and corrosion from various reactants, products, and / or byproducts. While supporting ceramic spheres have been described, it will be understood that spheres 142, 144 may have more or fewer spheres and may comprise support structures of different shapes or sizes, such as rings, cylinders, polygons, or others.

[0146] In some embodiments, a portion 141 of the catalyst bed 140 may have or define a first height 148 corresponding to the height of the unreduced catalyst and a second height 146 corresponding to the height of the reduced catalyst.

[0147] While portion 141 of catalyst bed 140 may comprise catalyst particles of a single size and / or shape, it is understood that, within the scope of this disclosure, it is conceivable to provide different portions of catalyst particles of different sizes and / or shapes within catalyst bed 140. Catalyst particles may have any suitable shape or configuration, such as spheres, granules, cylinders, cloverleaf shapes, tetraclove shapes, pyramids, cones, stars, etc., and may have any suitable number and size of openings passing through them, and / or grooves or channels formed on a portion of their surface. Different portions corresponding to a single, different type of catalyst size and / or shape may be provided within catalyst bed 140, for example, as axial or radial layers or bags. In some embodiments, catalyst particles of different sizes and shapes may be provided and mixed together within the catalyst body in any suitable configuration.

[0148] The catalyst particles in catalyst bed 140 may have some of the functions of and operate in conjunction with the supporting ceramic balls in 142 and 144, or vice versa. In some embodiments, the catalyst particles are selected independently of the supporting ceramic balls.

[0149] exist Figure 6 and 7The diagram shows a tube bundle 130 according to one embodiment. The tube bundle 130 is configured to extend substantially longitudinally within a housing 102 about an axis 1A-1A and is held from top to bottom by a top plate and tube support plate 150, a plurality of tube support plates 162, 163, 164, 165, a catalyst support plate 154, and a gas inlet plate 156. The distance 161 between the top plate and tube support plate 150 and tube support plate 162, and the distance 161 between tube support plates 162, 163, 164, and 165, can be uniform along the length of the tube bundle 130. In some embodiments, this distance 161 can vary. The distance 167 between tube support plate 165 and catalyst support plate 154 can be greater than distance 161. The distance 169 between catalyst support plate 154 and gas inlet plate 156 can be less than distance 167. It is understood that the described embodiments are merely exemplary, and any configuration of the tube bundle 130 can be used.

[0150] Tubes 131 may define a uniform thickness and diameter along the longitudinal length of tube bundle 130. In some embodiments, tubes 131 have a tapering thickness along the length of the tube bundle and an increasing thickness and / or diameter near one or more of plates 150, 162, 163, 164, 165, 154, 156 to support the plates. In some embodiments, one or more tubes 131 of tube bundle 130 may have a greater thickness relative to other tubes 131 to enhance structural support. For example, tubes 131 extending near the center or outer edge of tube bundle 130 may have a greater thickness relative to other tubes, such as 10%, 20%, 25%, 33%, 50%, or any other suitable thickness, that is, the walls of these tubes 131 may have an increased thickness while maintaining the same inner diameter in some embodiments. This advantageously allows tubes 131 with increased thickness to deliver reactants while supporting tube bundle 130, thereby releasing cross-sectional area relative to other structural settings to increase catalyst loading and allow for more uniform catalyst distribution.

[0151] In some embodiments, the tubes 131 have a smaller thickness and / or an increased diameter near the bottom of the reactor 100 compared to the top of the reactor 100, in order to, for example, facilitate more efficient heat transfer at the bottom of the reactor 100. Alternatively, one or more tubes 131 of the tube bundle 130 may include internal tubular rods configured to increase the rate at which reactants are preheated therein. The internal tubular rods may extend a portion or all of the distance from the bottom to the top of the tube 131.

[0152] The tube bundle 130 and reactor 100 are typically designed and implemented in a modular manner. Existing shell-and-tube reactors are not easily scaled up due to the significant rework required to achieve a proper balance between tube length and diameter, catalyst bed, shell, and other components. The design of reactor 100 advantageously allows for scaling up or down depending on the arrangement of the concentric bands of tubes 131 on the tube bundle 130. The tube bundle 130 is configured such that whether the circumferential bands of tubes 131 are increased (to increase the reactor design capacity to improve yield or during debottlenecking retrofits) or removed (to reduce the reactor design capacity), the other geometric features of the reactor remain unchanged. Therefore, extensive redesign work can be avoided.

[0153] The tube bundle 130 can be configured to maintain one or more geometric constraints or ratios in any design, whether the reactor and tube bundle are constructed in various designs to reduce or increase yield. To ensure improved tube density, the average tube spacing (i.e., the center-to-center distance between tubes) of the tube bundle can be substantially constant throughout the bundle, with circumferential bands and the tubes forming these bands spaced apart to maintain a constant tube spacing.

[0154] As another example, the tube bundle 130 advantageously achieves an ideal ratio of the cumulative cross-sectional area of ​​the catalyst bed to the cumulative cross-sectional area of ​​the tube 131 (i.e., the total radial surface area of ​​the tubes) when the reactor is viewed in a plan view. In some embodiments, the ratio of the cumulative cross-sectional area of ​​the catalyst to the cumulative cross-sectional area of ​​the tubes is between 2 and 20, more specifically between 5 and 12.

[0155] Whether the circumferential bands of tubes 131 are added or removed in the design of tube bundle 130, the cross-sectional area of ​​tubes 131 relative to the catalyst bed can be easily and readily adjusted to remain within a suitable range, thereby ensuring appropriate reactor performance (particularly its safety performance). In one embodiment, adding or removing the circumferential bands of one or more tubes may not significantly alter the ratio of the cumulative cross-sectional area of ​​the catalyst to the cumulative cross-sectional area of ​​the tubes. In other embodiments, tube bundle 130 may be designed to target any other geometric or process-related parameters, whereby removing or adding the circumferential bands of the tubes does not require extensive redesign, but rather allows engineers to easily and readily adjust the reactor to achieve new, desired capacities or other requirements. By providing tube bundle 130 with a specific relationship between the cross-sectional areas of the tubes and the catalyst bed, heat distribution can be improved, which reduces the likelihood of runaway reactions by reducing hot spots and increasing the overall yield of reactor 100.

[0156] Reactor 100 can be controlled and maintained during operation to control one or more characteristics of the catalyst bed 140 and / or tube bundle 130. In some embodiments, reactor 100 is configured to utilize temperature measuring devices to assess the heat distribution over the cross-sectional area of ​​the entire catalyst bed. In particular, reactor 100 can be controlled by assessing the radial temperature gradient within the reactor based on depth and / or by assessing the growth of the gradient based on depth within reactor 100 (from the upper end 105 to the lower end 107).

[0157] Let's take a look Figure 12 and 13 The catalyst support plate 154 is configured to support the total height of the solid catalyst, for example, the combination of the heights of portions 142 and 144 and the height of portion 141. The catalyst support plate 154 also advantageously supports forces generated by the pressure differential across the catalyst bed 140. The catalyst support plate 154 may be positioned within the housing 102 near the catalyst unloading nozzle 116 and / or handhole 118. The catalyst support plate 154 may define one or more openings 180, 181. Openings 180, 181 may include or define openings comprising a plurality of openings corresponding to a first size of opening 180 and a plurality of openings corresponding to a second size of opening 181, these openings extending through at least a portion of the thickness of the catalyst support plate 154.

[0158] A first dimension of the opening 180 may correspond to the circumference of at least one tube 131 of the tube bundle 130. In some embodiments, the first dimension of the opening 180 is larger than the circumference of the tube 131 to allow for a degree of movement and / or thermal expansion of the tube within the opening 180. The opening 180 may be defined to pass through the catalyst support plate 154, depending on the arrangement of the plurality of tubes 131 in the tube bundle 130. A second dimension of the opening 181 may be smaller than the first dimension of the opening 180, and the second-sized opening 181 is used to allow reactants, reaction products, and reaction byproducts to flow through in the process toward the outlet nozzle 124.

[0159] In some embodiments, one or more openings 180 may define a terminal for a temperature measuring device. The opening 182 is sized and configured to receive a thermocouple insert 126 and terminate the extension of the thermocouple insert 126. Figure 7 In some embodiments, the opening 182 may extend only partially into the thickness of the catalyst support plate 154. In some embodiments, the thermocouple insertion tube 126 may be welded to the catalyst support plate 154 and plugged there. The tube 131 may not be welded to the catalyst support plate 154 to accommodate the effects of thermal expansion.

[0160] The size of the opening 181 and / or the average distance between the openings 181 can be a function of the thickness of the catalyst support plate 154. Thus, the size of the opening 181 is directly proportional to the thickness of the catalyst support plate 154, and / or the distance between the openings 181 is inversely proportional to the thickness of the catalyst support plate 154. That is, the greater the thickness of the catalyst support plate 154, the larger the diameter of the opening 181 and / or the smaller the distance between the openings 181. In some embodiments, the thickness of the catalyst support plate 154 can be between 20 and 500 mm, more specifically between 50 and 300 mm, and in some embodiments 110 mm, while the diameter of the opening 181 can be between 1 and 50 mm, more specifically 5 to 25 mm, and in some embodiments 10 mm.

[0161] like Figure 13 As shown in the partially enlarged view, the openings 180 can extend in a pattern or arrangement corresponding to the arrangement of the tubes 131 in the tube bundle 130, which will be discussed in more detail below. Openings 181 can extend between each opening 180. Openings 181 can define any suitable pattern or arrangement, such as an extension direction 183A and / or a lateral extension direction 183B, wherein extension directions 183A, 183B are defined as straight lines. Other patterns or arrangements of openings 181 are also conceivable within the scope of this disclosure. Openings 181 can be spaced apart from each other at any suitable distance. In some embodiments, the center-to-center distance between adjacent openings 181 is 1-30 mm, more specifically, the center-to-center distance is 5-20 mm. In some embodiments, the center-to-center distance between adjacent openings 181 in one or both directions 183A, 183B is 15 mm. The center-to-center distance between adjacent openings 181 does not need to be uniform across the entire surface of the catalyst support plate 154, but can vary appropriately.

[0162] The catalyst support plate 154 may define a material strip 184 at its outer periphery, which forms an area in the catalyst support plate 154 that does not define any openings 180, 181. The strip 184 may extend partially or entirely around the outer periphery of the catalyst support plate 154 and advantageously facilitate welding or other suitable connection between the catalyst support plate 154 and the inner surface of the housing 102. In some embodiments, the strip 184 may extend into a groove defined by the inner surface of the housing 102 and then be welded thereto. The strip 184 may extend for any suitable distance, for example, 5 mm radially.

[0163] Let's take a look Figure 11A gas inlet plate 156 may be disposed below the catalyst support plate 154 and may include a plurality of openings 155 defined to extend through at least a portion of the thickness of the gas inlet plate 156. The plurality of openings 155 may be circular openings defined to extend through the gas inlet plate 156 according to the arrangement of the plurality of tubes 131 of the tube bundle 130, and correspond to the arrangement of openings 180 in the catalyst support plate 154. In one embodiment, the gas inlet plate 156 is substantially solid except for the plurality of openings 155, without openings to force the incoming reactants into the tubes 131. The plurality of tubes 131 may be hermetically welded and / or strength welded to the gas inlet plate 156. It will be understood that when discussing welding one component to another herein, hermetically welded, strength welded, or combined, or any other type of connection, may be considered.

[0164] Let's take a look Figure 8 and 9 The reactor 100 may also include at least one tube support plate 150, 162, 163, 164, 165, which may be arranged longitudinally spaced along the axial or longitudinal length of the tube bundle 130. Although tube support plates 150, 162, 163, 164, 165 have been shown and described, it will be understood that more or fewer support plates may be provided. The top feed tube support plate 150 may be substantially the same as tube support plates 162, 163, 164, 165, and may include or omit one or more features. For example, the top feed tube support plate 150 may have the same features as tube support plates 162, 163, 164, 165, and may further include one or more spacers configured to cooperate with the top plate, which will be described in more detail below.

[0165] Tube support plates 150, 162, 163, 164, and 165 may include at least one circumferential band 168 configured to hold at least one tube 131 in position. The at least one circumferential band 168 includes at least one bracket 172 configured to extend around a portion of the tube 131 of the tube bundle 130. In some embodiments, the at least one bracket 172 extends around the entire portion of the tube 131. The bracket 172 may be configured to be releasably connected to the tube 131.

[0166] In some embodiments, the support 172 may extend only around a portion of the tube rather than the entire tube. The support 172 may advantageously cooperate with a beam 173 extending between the support 172 and an adjacent support 172 connected to an adjacent tube 131. The support 172 may be releasably or non-releasably connected to the beam 173, and may define, for example, a rounded connection. A circumferential band 168 may be defined by a series of interconnected supports 172 and beams 173, which define a substantially circumferential arrangement with the corresponding tubes 131.

[0167] The circumferential band 168 may be arranged concentrically with the adjacent circumferential bands 168 of the tube support plates 150, 162, 163, 164, and 165, optionally centered on the longitudinal axis 1A-1A of the reactor. The cooperation of the support 172, beam 173, radial strut 166, and circumferential band 168 together defines the tube support plate. Although the circumferential band 168 has been shown and described, it is understood that any suitable configuration, including asymmetrical, staggered, or non-circumferential arrangements, can be used. Although the cooperation of the various components is described as defining the tube support plate, it is understood that the tube support plate can take any suitable configuration and is not limited thereto.

[0168] At least one tube support plate 150, 162, 163, 164, 165 defines at least one radial strut 166, which is connected to at least one circumferential band 168 at connection point 169, and / or to an outer support band 170 at connection point 171. The tube support plate may define a plurality of radially symmetrically arranged radial struts 166, for example, in increments of 22.5°, 30°, 45°, 90°, 120°, 180°, another increment evenly divided into 360° increments, or others. In other embodiments, the radial struts 166 are arranged asymmetrically in any suitable manner.

[0169] The outer support band 170 may define a substantially continuous band of support material (e.g., stainless steel) that provides sufficient rigidity, strength, and / or support for the tube support plate, and / or facilitates the connection of the outer support band 170 to the inner surface of the reactor shell 102. Although in Figure 9 The embodiments shown in Figure 10 illustrate and describe eight radial struts 166; however, it is understood that more or fewer radial struts 166 may be provided, and all tube support plates 150, 162, 163, 164, 165 need not have the same number or arrangement of radial struts or other components.

[0170] The radial strut 166 may extend straight outward from the center of the tube support plate to the outer support band 170, or may be defined as curved, bent, meandering, or other constructions. The radial strut 166 may be formed of any suitable material, such as stainless steel, and may provide heat resistance to maintain the required stiffness and strength under reactor conditions. The radial strut 166 advantageously defines a connection point 169 between the circumferential band 168 and the radial strut 166. The connection point 169 may be releasable or non-releasable and may define any suitable connection, such as being welded together or connected by suitable fasteners. The tube support plate may be configured to move with the tube 131 by thermal expansion and contraction and may be formed of a high-temperature resistant material, such as steel (e.g., stainless steel), ceramics, polymer materials, composite materials, or others.

[0171] In some embodiments, the tube support plates 150, 162, 163, 164, and 165 may be manufactured using any suitable method. In some embodiments, the tube support plates 150, 162, 163, 164, and 165 are formed from a single solid plate, for example, by removing material therefrom through waterjet cutting. In other embodiments, the radial struts and circumferential bands are manufactured and assembled separately to form the tube support plates.

[0172] The top feed tube support plate 150 may additionally define one or more spacers 174 on its top surface. The spacers 174 may be attached to one or more structures of the top feed tube support plate 150 by any suitable means, including by welding. The spacers 174 may extend to a predetermined height and may define an opening within their central portion. The opening may include one or more threads configured to engage with one or more threads of a fastener, which will be discussed in more detail below with respect to the top plate 190. The spacers 174 may extend around the top feed tube support plate 150 in any suitable arrangement and in any suitable number.

[0173] For example, when spacer 174 is connected to radial support 166, spacer 174 may define three concentric annular patterns 175 around the top feed tube support plate 150. Figure 9 In one embodiment, spacers 174 extend along four radial struts 166 between the first and second circumferential bands, between the seventh and eighth circumferential bands, and between the thirteenth and eleventh circumferential bands. A total of four spacers 174 may be provided on each concentric annular pattern 175 such that the corner of each segment of the top plate 190 can be secured thereto, as described below.

[0174] The arrangement of the radial struts 166 advantageously provides a reliable connection of the tubes 131 of the tube bundle 130 while minimizing disturbance to the catalyst distribution when the catalyst is loaded from the top 105 of the reactor 100. For example, the radial struts 166 are configured to minimize uneven distribution of the catalyst when the catalyst particles are poured into the housing 102. In some embodiments, the radial struts 166 of adjacent tube support plates 162, 163, 164, 165 may be axially aligned along the longitudinal extension of the reactor 100.

[0175] In other embodiments, such as Figure 10B As shown, the radial struts 167 of adjacent tube support plates may be offset from the radial struts 166 to promote uniform distribution of the catalyst during loading. The degree of offset can be any suitable degree. In some embodiments, the radial struts 167 are offset by a distance equivalent to half the angular distance between the radial struts 166. Figure 10BIn the illustrated embodiment, radial struts 166 are offset from each other by 45°, and radial struts 167 are offset by 22.5°. Subsequent tube support plates can be arranged alternately. The radial struts 166 of adjacent tube support plates can be offset along the longitudinal length of the reactor to define a spiral or coiled pattern. The described embodiment is exemplary, and any other arrangement may be suitably used.

[0176] The tube bundle 130 may be configured such that the innermost circumferential band 168A of at least one tube support plate includes six supports configured to loops corresponding to the six innermost tubes of a first dimension. The first dimension may be, for example, a diameter of 0.5-3 mm, more specifically, a diameter of 1-2 mm, and in some embodiments, 1.5 mm. The second circumferential band 168B of at least one tube support plate includes 10 supports configured to loops corresponding to 10 tubes of the tube bundle of the first dimension. The third circumferential band 168C of at least one tube support plate includes 14 supports configured to loops corresponding to 14 tubes of the tube bundle of the second dimension. The second dimension may be, for example, a diameter of 0.5-5 mm, more specifically, 1-4 mm, and in some embodiments, 2.5 mm.

[0177] At least one tube support plate has a fourth circumferential band 168D comprising 18 supports configured to loop around 18 tubes of a first-size tube bundle. At least one tube support plate has a fifth circumferential band 168E comprising 22 supports configured to loop around 22 tubes of a first-size tube bundle. At least one tube support plate has a sixth circumferential band 168F comprising 26 supports configured to loop around 26 tubes of a first-size tube bundle.

[0178] At least one tube support plate has a seventh circumferential band 168G comprising 30 supports configured to loop around 30 tubes of a second-sized tube bundle. At least one tube support plate has an eighth circumferential band 168H comprising 34 supports configured to loop around 34 tubes of a first-sized tube bundle. At least one tube support plate has a ninth circumferential band 168I comprising 36 supports configured to loop around 36 tubes of a first-sized tube bundle. At least one tube support plate has a tenth circumferential band 168J comprising 42 supports configured to loop around 42 tubes of a first-sized tube bundle.

[0179] At least one tube support plate has an eleventh circumferential band 168K comprising 46 supports configured to loop around 46 tubes of a second-size tube bundle. At least one tube support plate has a twelfth circumferential band 168L comprising 50 supports configured to loop around 50 tubes of a first-size tube bundle. At least one tube support plate has a thirteenth circumferential band 168M comprising 54 supports configured to loop around 54 tubes of a first-size tube bundle. At least one tube support plate has a fourteenth circumferential band 168N comprising 58 supports configured to loop around 58 tubes of a second-size tube bundle.

[0180] While the first through fourteenth circumferential bands have been shown and described, it is understood that the reactor embodiments of this disclosure advantageously facilitate a modular reactor structure, which can better adapt to the varying production requirements of different facilities than existing reactor designs. For example, engineers can modify the described tube bundle 130 as needed to have more, fewer, and / or different circumferential bands. To scale up the tube bundle 130 and the entire reactor 100 to accommodate higher annual plant output (e.g., during debottlenecking operations), additional circumferential bands can be added to increase the number of tubes, and the tube bundle can be extended outwards with simple modifications. For example, the connection 171 between the radial strut 166 and the outer band 170 can be released, allowing additional circumferential bands to be added to the tube support plate, i.e., the outer band 170 is replaced by the new circumferential band. For this purpose, the outer band 170 can be constructed with an expandable circumference.

[0181] Conversely, to reduce the size of reactor 100, the circumferential belt, such as the outermost circumferential belt, can be removed to reduce the size of the tube bundle, so as to fit a smaller reactor shell and / or produce a correspondingly lower annual plant output. This can be achieved, for example, by removing the connector 169 between the circumferential belt and the radial struts.

[0182] Furthermore, the arrangement of the circumferential band, as shown in the figure, allows for the addition or removal of the circumferential band and its associated supports and tubes, while also accommodating the structure of the radial struts. As illustrated, the circumferential band increases the number of supports and tubes, resulting in a substantially uniform distribution of the tubes and sufficient space between them to allow catalysts and reactants to pass through. It also allows for the addition or removal of the circumferential band without substantially altering the design of the radial struts and tube support plates.

[0183] In one embodiment, the ninth circumferential band 168I (or any other) of at least one tube support plate further includes a bracket 172 corresponding to at least one thermocouple insertion tube 126 of a first tube size. Providing a bracket 172 for the thermocouple insertion tube 126 allows for the insertion of a temperature measuring device into the tube bundle, preferably into the area surrounded by the catalyst and tubes, to provide accurate temperature readings along the longitudinal length of the reactor.

[0184] Similar to tube support plates 162, 163, 164, and 165, the top feed tube support plate may include one or more radial struts 166, an outer band 170, and one or more supports 172 configured to engage with and / or surround the tube 131 of the tube bundle 130. The radial struts 166 of the top feed tube support plate 150 may be arranged similarly or correspondingly to the struts 166 of the feed tube support plates 162, 163, 164, and 165, and may be positioned at an appropriate angle 176 (…). Figure 9 The angle can be divided axially, for example, at 45°. It is understood that other angles or settings may also be considered in this disclosure.

[0185] The support 172 of the top feed tube support plate 150 may be formed or extended near the end of the tube 131, where the preheated reactants flow out of the tube 131 and then flow downwards in the second direction F2. Thermocouple insertion tube 126 may extend a distance above the uppermost end of the tube 131, facilitating the insertion of a temperature measuring device from the thermocouple port 106 into the thermocouple insertion tube 126. Similar to tube supports 162, 163, 164, and 165, the top feed tube support plate 150 may be configured to be enlarged or reduced in size to suit the required capacity of the reactor 100.

[0186] The arrangement of tube bundle 130 and tube support plates 150, 162, 163, 164, 165 can advantageously take into account the heat transfer and reactor kinetics of the reactor.

[0187] Let's take a look Figures 14 to 16 The top plate 190 is shown. The top plate 190 may be configured to be mounted on or above a top feed pipe support plate 150. The top plate 190 may be structurally modular and defines four distinct sections 192 surrounded by flanges 191. The top plate 190 may define plate edges 194, one or more orifices 202 defined to extend through at least a portion of the thickness of the plate 190, and one or more gas openings 204 defined to extend through at least a portion of the thickness of the plate 190. The orifices 202 may be configured to be generally aligned with the arrangement of the tubes 131 of the tube bundle 130 and to facilitate the exit of preheated reactants from the tubes 131 into the space 113 of the reactor 100. Figure 5B ).

[0188] Gas opening 204 facilitates the entry of preheated reactants into catalyst bed 140 and ensures appropriate flow distribution. Top plate 190 can be configured to generate a small pressure drop to make the flow into catalyst bed as uniform as possible. Compared to existing methods that utilize heavy and / or complex designs (which are difficult to manufacture or operate for maintenance purposes, and / or associated with high costs), top plate 190 is advantageously configured to achieve improved uniformity of flow distribution using the simplified design shown and described.

[0189] Because the top plate 190 extends outward to the flange 191, the gas opening 204 can extend substantially to the edge 194, without leaving a gap like the catalyst support plate 154. The thickness of the top plate 190 can be reduced compared to the catalyst support plate 154. In some embodiments, the thickness of the top plate 190 is between 1 and 25 mm, more specifically, between 5 and 15 mm, and in some embodiments, 8 mm.

[0190] The top plate 190 is configured to be detachably connected to the housing 102 and / or the top feed tube support plate 150 by any suitable mechanism, for example by using corresponding holes 193 at the edges of the various portions of the top plate 190. Figure 15 Fasteners 196 of the top plate 190 may mate with one or more spacers 174 extending between the top plate 190 and the top feed tube support plate 150, and may be welded (e.g., adhesive welded) to the top tube support plate 150.

[0191] In some embodiments, spacer 174 may have sufficient height and / or circumference to receive the mating end of fastener 196 within a track or groove formed to extend through a portion of the thickness of spacer 174, allowing the top plate 190 to be securely attached to the top feed tube support plate 150. The height of spacer 174 may be between 1 and 30 mm, more specifically between 5 and 20 mm, and in some embodiments 15 mm. Spacer 174 may be welded to radial strut 166, circumferential band 168, bracket 172, or other locations. As shown, fastener 196 and corresponding spacer 174 may be positioned such that fastener 196 and spacer 174 are provided at each corner of top plate 190 and along the inner edge of portion 194.

[0192] The top plate 190 may further include or cooperate with one or more load rings 195. The load ring 195 can be any suitable component configured to facilitate positioning and / or removal of portion 194 of the top plate 190. The load ring 195 may be connected via one or more gas openings 204, or at any other suitable location, and defines components for removably attaching to and manipulating the top plate 190. In some embodiments, the load ring 195 is configured to allow an operator to grasp the top plate 190 with a tool to lift the top plate 190 from the reactor housing 102.

[0193] By providing the top plate 190 in a modular manner, and by giving the top plate 190 different sections 194, the top plate 190 is easier to disassemble and replace during maintenance operations without sacrificing its ability to dispense reactants and fix the catalyst bed 140. The modular structure of the top plate 190 further reduces the cost and complexity of the manufacturing process, as identical sections 192 can be manufactured instead of a monolithic plate 190. One advantage of the top plate 190 is that plant workers can stand on one of the sections 194 of the top plate 190 while loading the catalyst through the openings provided by the removed section 194.

[0194] Let's take a look Figure 17-19 The diagram shows and describes a retaining plate 210 that can be used with one or more nozzles of reactor 100. The retaining plate 210 can secure the catalyst unloading nozzle 116 and / or handhole 118. The retaining plate 210 may include a handle 212 and is configured to mate with a lip 214 defined by the nozzle 116. In some embodiments, the nozzle 116 defines a plurality of lips 214 arranged circumferentially around the opening of the nozzle in any suitable manner, and the retaining plate 210 is configured to abut against the inner surface of the lips 214, such as... Figure 17 As shown. In some embodiments, the lips 214 are spaced at angles, such as 15 degrees, 20 degrees, 30 degrees, 45 degrees, 60 degrees, 90 degrees, or other angles. The arrangement of the lips 214 can be symmetrical or asymmetrical. The flange 117 of the nozzle 116 may define one or more openings 211 through which suitable fasteners can be received to connect the nozzle 116 to a suitable valve core.

[0195] In some specific embodiments, the plurality of lips 214 do not extend around the lowest portion B of the circumferential opening defined by the catalyst unloading nozzle 116 or handhole 118. Instead, as Figure 19 As shown, the bottom part B is unobstructed, allowing the catalyst particles to flow freely under gravity during catalyst unloading. The limiting plate 210 effectively prevents the catalyst from flowing too fast during unloading.

[0196] Let's take a look Figure 20 The figure shows and describes a reactor 300 according to one embodiment. The series of reference numerals 300 may include features similar to or identical to the series of reference numerals 100 already described. The reactor 300 includes a housing 302 in which a tube bundle having a top plate 350 as described above can be received and secured, and defines an inlet nozzle 320 and an outlet nozzle 324. The housing 302 may also include or cooperate with a dome-shaped head 304, which defines and / or supports a thermocouple insertion nozzle 306. The dome-shaped head 304 may be secured to the housing 302 via a flange 312. The reactor 300 extends longitudinally about axis 20A-20A. A catalyst bed 340 may extend to a suitable height within the internal space defined by the reactor housing 302.

[0197] Reactor 300 also defines a thermocouple insertion tube 326 that extends around, or is substantially parallel to or aligned with, the longitudinal axis 20A-20A and passes through the catalyst bed 340. The thermocouple insertion tube 326 may be integrated with or separate from the tube bundle described above. The thermocouple insertion tube 326 is configured to receive a temperature measuring device 310, which also extends around the longitudinal axis 20A-20A. The temperature measuring device 310 may be a multi-point thermocouple. This multi-point thermocouple is configured to obtain temperature measurements at multiple locations along reactor 300.

[0198] like Figure 20 As shown, the temperature measuring device 310 may include eight measuring positions 382A, 382B, 382C, 382D, 382E, 382F, 382G, and 382H along the length of the reactor 300, extending to an end point 327. The temperature measuring device 310 may have a total length 330I. The positions 382A, 382B, 382C, 382D, 382E, 382F, 382G, and 382H may be spaced apart by distances 330A, 330B, 330C, 330D, 330E, 330F, and 330G, respectively. The distances 330A, 330B, 330C, 330D, 330E, 330F, and 330G may be the same distance, such that the measuring positions are evenly spaced along the reactor 300, or they may be different distances depending on the requirements of a specific process.

[0199] Thermocouple insertion tube 326 may be suitably configured to allow temperature measuring device 310 to obtain readings at positions 382A, 382B, 382C, 382D, 382E, 382F, 382G, and 382H, for example, by defining openings in the thermocouple insertion tube 326 at or near positions 382A, 382B, 382C, 382D, 382E, 382F, 382G, and 382H, to allow temperature measuring device 310 to measure the temperature inside the reactor. While temperature measuring devices have been described, it is understood that the scope of this disclosure can be extended to other types of sensors and is not limited to multi-point thermocouples. In some embodiments, different sensors may be positioned at different locations as needed.

[0200] The temperature measuring device 310, reactor 300, and thermocouple insertion tube 326 advantageously facilitate improved process control by providing particulate reactor condition data at multiple locations within the reactor while minimizing the risk of leakage, particularly for high-pressure and / or high-temperature environments and / or reactions involving hydrogen or oxygen-sensitive catalysts, and reducing the number of thermocouple connections. The configuration of the temperature measuring device 310, reactor 300, and thermocouple insertion tube 326 further enhances the scalability of reactor design because the arrangement of the thermocouple insertion tube 326 and temperature measuring device 310 allows for accurate readings of internal reactor conditions regardless of reactor size. This alleviates the difficulty of monitoring the reactor (where thermocouple wells are radially positioned from the reactor's sidewall surface) and, for larger reactors, enables disproportionate measurement of conditions near the outer shell rather than near the reactor center.

[0201] In addition, at least as Figure 2 and Figure 7 As shown, the reactor may include multiple temperature measuring devices. These temperature measuring devices can be positioned relative to the reactor shell and relative to each other in any suitable configuration. For example, in... Figure 2 and Figure 7 In the illustrated embodiment, the temperature measuring devices can be offset from the central longitudinal axis of the reactor by the same distance and positioned relative to each other. The distance between the temperature measuring devices can be configured to minimize interference or disturbance to the heat distribution within the reactor, particularly to the catalyst bed. This distance can be selected above a minimum threshold below which hot spots will appear between or near the temperature measuring devices due to disturbances to the reactant and product flows and their corresponding heat distribution. Therefore, setting the temperature measuring devices above this minimum threshold avoids reactor performance interruptions and improves measurement accuracy.

[0202] Temperature measuring devices can be used for different purposes and / or can complement each other. Figure 2 and Figure 7In the illustrated embodiment, the temperature measuring device is a multi-point thermocouple, such as for... Figure 20 The aforementioned multi-point thermocouple can be connected to a process control system, while a second multi-point thermocouple can be connected to a safety instrument system.

[0203] Providing multiple multipoint thermocouples advantageously confirms temperature measurements at specific locations (i.e., heights) within the reactor. Any discrepancies between the signals obtained from the multipoint thermocouples can, for example, be used to determine the development of hot spots at a specific height, allowing operators to make adjustments as necessary. It is understood that any suitable number of thermocouples can be used with any appropriate configuration.

[0204] One embodiment of the reactor includes a plurality of feed tubes extending longitudinally through the reactor and the catalyst bed. A tube bundle may define thermocouple inserts extending parallel to the feed tubes, configured to receive temperature measuring devices, such as multi-point thermocouples. The thermocouple inserts may be configured to extend at different distances from the center of the reactor.

[0205] These distances can be configured to allow for the measurement of temperature distribution at varying distances from the center. In particular, this can facilitate the validation of reactor designs at specific scales, further enhancing the scalability of the reactors in the embodiments of this disclosure. This also enhances process control of the reactor, improves the granularity of temperature measurements, and allows for the customization of relevant responses using a process control system. In some embodiments, the radial configuration of the thermocouple insert can be determined to match predicted hot spots.

[0206] This allows operators to quickly and accurately determine when hotspots form and respond accordingly, thus preventing runaway reactions. The construction of the thermocouple inserts can be further determined relative to the tube bundle to accommodate the size of the reactor shell. For example, fewer thermocouple inserts can be used in smaller reactors, while in larger reactors, the number of thermocouple inserts and the complexity of their construction may increase.

[0207] By providing a reactor according to the disclosed embodiments, the problems of existing reactors being difficult to access when maintenance is required and difficult to scale up to meet the production demands of a facility are addressed. The reactor embodiments of this disclosure advantageously provide a reactor comprising robust yet flexible internal components configured for modular arrangement according to the production demands of the facility design, facilitating access for maintenance and catalyst loading, improving the uniform distribution of catalyst, reactants, and heat, and / or providing robust structural support during construction, transport, installation, and operation.

[0208] Although the reactor has been shown and described in detail in the accompanying drawings and the foregoing description, it should be regarded as illustrative rather than restrictive. It is self-evident that only preferred embodiments have been shown and described herein, and all variations, equivalents and modifications falling within the spirit and scope of the embodiments as defined by the claims are intended to be protected.

[0209] Therefore, the features of the disclosed embodiments can be combined or arranged to achieve specific advantages that can be understood by those skilled in the art from this disclosure. Similarly, the features of the disclosed embodiments can provide independent advantages applicable to other embodiments not detailed herein. In particular, any feature from one disclosed embodiment can be used in other disclosed embodiments.

[0210] It should be understood that not all objectives or advantages may be achieved under any embodiment of this disclosure. Those skilled in the art will recognize that the system and method 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.

[0211] Those skilled in the art will recognize the interchangeability of the various features disclosed. In addition to the described variations, those of ordinary skill in the art can mix and match other known equivalents of each feature. Those skilled in the art will understand that the features are applicable to other types of reactors, reaction fittings, chemical products, and processes. Therefore, this disclosure and its embodiments and variations are not limited to methanol synthesis processes or shell-and-tube reactors, but are applicable to any chemical process.

[0212] While this disclosure describes certain exemplary embodiments and examples of reactors, those skilled in the art will understand that this disclosure extends beyond the specific disclosed embodiments to other alternative embodiments and / or the use of this disclosure and its obvious modifications and equivalents. This disclosure should not be limited to the specific disclosed embodiments described above.

[0213] Furthermore, unless otherwise stated, the numerical expressions used to describe quantities, components, distances, or other measurements as used in this specification and claims should be understood as optionally modified by the term "about" or its synonyms. When the terms "about," "approximately," "generally," or similar terms are used with the stated quantity, value, or condition, they can be understood as deviations from the stated quantity, value, or condition of less than 20%, less than 10%, less than 5%, less than 1%, less than 0.1%, or less than 0.01%. As used herein, the term "between" includes any of the referenced endpoints. For example, "between 2 and 10" includes 2 and 10.

Claims

1. A reactor, comprising: The outer shell defines the internal space configured to receive the catalyst; At least one inlet nozzle; as well as The tube bundle comprises a plurality of tubes arranged concentrically around the longitudinal axis of the reactor. The reactor further includes at least one tube support plate, the at least one tube support plate including at least one circumferential band, the at least one circumferential band including at least one support that extends around a portion of the tube in the tube bundle.

2. The reactor according to claim 1, characterized in that, The reactor also includes at least one of a catalyst support plate, a gas inlet plate, and a top plate.

3. The reactor according to claim 1, characterized in that, The catalyst is a solid catalyst, which comprises spheres of a first diameter.

4. The reactor according to claim 3, characterized in that, The solid catalyst also includes spheres of a second diameter.

5. The reactor according to claim 4, characterized in that, The reactor further includes a catalyst support plate, wherein catalyst balls of a first diameter and catalyst balls of a second diameter are disposed in discontinuous, respective layers near the catalyst support plate.

6. The reactor according to claim 1, characterized in that, The shell is configured to receive at least one solid catalyst, wherein the solid catalyst comprises a shape defining at least one of granular, cyclic, flake, or spherical shapes.

7. The reactor according to claim 1, characterized in that, The reactor also includes a catalyst support plate, wherein the catalyst support plate is configured to support a solid catalyst at a certain height.

8. The reactor according to claim 1, characterized in that, The reactor also includes a catalyst support plate, wherein the catalyst support plate defines one or more openings.

9. The reactor according to claim 8, characterized in that, The one or more openings include a plurality of first-sized openings and a plurality of second-sized openings, which extend through at least a portion of the thickness of the catalyst support plate.

10. The reactor according to claim 9, characterized in that, The first dimension corresponds to the circumference of at least one tube of the tube bundle, while the second dimension is smaller than the first dimension.

11. The reactor according to claim 10, characterized in that, The opening of the first size is defined to pass through the catalyst support plate according to the arrangement of the plurality of tubes of the tube bundle.

12. The reactor according to claim 1, characterized in that, The reactor further includes a gas inlet plate, wherein the gas inlet plate includes a plurality of openings defined to extend through the thickness of the gas inlet plate, the plurality of openings being circular openings defined to extend through the gas inlet plate according to the arrangement of a plurality of tubes of the tube bundle.

13. The reactor according to claim 12, characterized in that, The gas inlet plate also includes a second plurality of openings defined to extend through the thickness of the gas inlet plate, the second plurality of openings having a size and / or shape different from the plurality of circular openings.

14. The reactor according to claim 1, characterized in that, The at least one tube support plate defines a plurality of concentric circumferential bands.

15. The reactor according to claim 14, characterized in that, The at least one tubular support plate defines at least one radial strut connected to at least one of the plurality of circumferential belts.

16. The reactor according to claim 14, characterized in that, The innermost circumferential band of the at least one tube support plate includes a given number of supports, the supports being constructed as concentric band loops corresponding to the same given number of tubes at the innermost part of the tube bundle, and The second circumferential band of the at least one tube support plate includes a number of supports equal to or greater than the innermost circumferential band, the supports being configured to correspond to a corresponding number of tubes in the second concentric band ring of the tube bundle.

17. The reactor according to claim 16, characterized in that, One of the circumferential bands of the at least one tube support plate further includes a bracket corresponding to at least one thermocouple insertion tube, wherein the at least one thermocouple insertion tube is configured to receive a temperature measuring device configured to obtain the temperature at a plurality of longitudinal locations within the reactor.

18. A methanol synthesis reactor, comprising: The outer shell defines the internal space configured to receive a solid catalyst; A tube bundle, comprising a plurality of tubes, wherein the tubes are arranged in a concentric band around the longitudinal axis of the reactor; and At least one inlet nozzle; An outlet nozzle is arranged near the bottom of the housing; A catalyst support plate, wherein the outlet nozzle is disposed below the catalyst support plate; Multiple tube support plates, wherein each tube support plate includes multiple circumferential bands, each circumferential band including at least one support configured to extend around the tubes of the tube bundle; Each tube support plate defines multiple radial struts, and each radial strut is connected between the circumferential bands of the tube support plate; Each radial strut is detachably fixed to at least one circumferential band of each tube support plate; and A gas inlet plate, wherein the gas inlet plate is positioned close to the inlet nozzle, and the inlet nozzle is arranged below the gas inlet plate.

19. The reactor according to claim 18, characterized in that, The tube bundle is configured to facilitate greater heat transfer near the bottom of the reactor compared to the top of the reactor.

Images