Reaction chamber for feedstock reactor

Abstract

A reaction chamber for a feedstock reactor, comprising: a housing defining a reaction volume and having a heat resistant refractory material; an inlet for allowing the feedstock to enter the reaction volume; an outlet for allowing a reaction product to exit the reaction volume, the reaction product being formed as a result of decomposition of the feedstock in the reaction volume; and a protective pad lining an inner surface of the housing and including a compliant shock-absorbing layer.

Description

Technical Field

[0001] The present disclosure relates to pyrolysis, and in particular to a reaction chamber for a feedstock reactor. Background Art

[0002] Thermal cracking is a process that decomposes a feed gas (such as a hydrocarbon) into its constituent elements (carbon and hydrogen in the case of hydrocarbons) in the absence of oxygen. The decomposition is triggered by raising the temperature of the feed gas sufficiently to the point where the chemical bonds of the elements of the feed gas are broken.

[0003] For example, such pyrolysis can be achieved by thermally contacting the raw gas with a hot fluid. For example, combustion products formed by burning a combustible fuel can be mixed with the raw gas. At sufficiently high temperatures, the mixing of the hot fluid with the raw gas and the transfer of heat energy from the hot fluid to the raw gas are sufficient to cause the raw gas to split and decompose.

[0004] During operation of the feedstock reactor, particularly when the number of reaction cycles is relatively high, the reaction chamber is exposed to high temperatures and pressures. These issues raise concerns about the fine refractory ceramics that are typically lined or otherwise included in the materials of the reaction chamber. Summary of the invention

[0005] According to a first aspect, a reaction chamber for a feedstock reactor is provided, comprising: a shell defining a reaction volume and comprising a heat-resistant refractory material; an inlet for allowing feedstock to enter the reaction volume; an outlet for allowing reaction products formed due to decomposition of the feedstock in the reaction volume to leave the reaction volume; and a protective liner lining the inner surface of the shell and comprising a compliant shock absorbing layer.

[0006] The protective liner may also include a first heat-resistant layer.

[0007] The first heat resistant layer may be positioned between the inner surface of the outer shell and the compliant shock absorbing layer.

[0008] The protective liner may also include a second heat resistant layer.

[0009] The first heat-resistant layer may be positioned between the inner surface of the outer shell and the compliant shock-absorbing layer. The compliant shock-absorbing layer may be positioned between the first heat-resistant layer and the second heat-resistant layer.

[0010] The heat-resistant refractory material may be ceramic.

[0011] The first heat-resistant layer may include metal.

[0012] The first heat-resistant layer may include one or more of: FeCr; TiZrMo; and a refractory metal.

[0013] The first heat-resistant layer may include metal.

[0014] The second heat-resistant layer may include one or more of: FeCr; TiZrMo; and a refractory metal.

[0015] The compliant shock absorbing layer may include one or both of ceramic fiber paper and FeCrAl mesh.

[0016] According to another aspect of the present disclosure, a method of protecting a reaction chamber for a feedstock reactor is provided, comprising: inserting a protective liner into the reaction chamber, wherein the protective liner comprises a compliant shock absorbing layer; and lining an inner surface of the reaction chamber with the protective liner.

[0017] The protective liner may also include a first heat-resistant layer.

[0018] The first heat resistant layer and the compliant shock absorbing layer may be cylindrical.The method may further include: before inserting the protective liner into the reaction chamber, forming the protective liner by positioning the cylindrical compliant shock absorbing layer around the first cylindrical heat resistant layer.

[0019] Forming the protective liner may also include positioning a second cylindrical heat resistant layer around the cylindrical compliant shock absorbing layer.

[0020] Forming the protective liner may include first positioning the cylindrical compliant shock absorbing layer around the second cylindrical heat resistant layer; and then positioning the first cylindrical heat resistant layer around the cylindrical compliant shock absorbing layer.

[0021] The protective liner may be resiliently biased such that after being inserted into the reaction chamber, the protective liner is biased to line the inner surface of the reaction chamber.

[0022] The protective pad may include a longitudinal opening extending from a first end of the protective pad to an opposing second end of the protective pad.

[0023] The longitudinal opening may define opposing first and second edges of the protective liner.Inserting the protective liner into the reaction chamber may include spring loading the protective liner by overlapping the first and second edges of the protective liner prior to inserting the protective liner into the reaction chamber.

[0024] The protective liner may also include one or more holes in the protective liner. Lining the interior surface of the reaction chamber with the protective liner may include aligning the one or more holes with one or more nozzles extending into the reaction chamber.

[0025] The present disclosure does not necessarily describe the entire scope of all aspects. Other aspects, features and advantages will be apparent to those of ordinary skill in the art after reading the following description of specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings, in which:

[0027] Figure 1 is a schematic diagram of a feedstock reactor being operated according to an embodiment of the present disclosure;

[0028] Figure 2A shows a cross section of a reaction chamber according to an embodiment of the present disclosure;

[0029] Figure 2B shows a tapered end portion of a heat-resistant layer of a protective liner according to an embodiment of the present disclosure;

[0030] Figure 2C shows a cylindrical heat-resistant layer of a protective liner according to an embodiment of the present disclosure;

[0031] FIG. 3A to FIG. 3C A protective liner according to an embodiment of the present disclosure is shown; and

[0032] Figure 4 A compliant shock absorbing material according to an embodiment of the present disclosure is shown. DETAILED DESCRIPTION

[0033] The present disclosure seeks to provide an improved reaction chamber for a feedstock reactor.While various embodiments of the present disclosure are described below, the present disclosure is not limited to these embodiments and variations of these embodiments may fully fall within the scope of the present disclosure which is limited only by the appended claims.

[0034] In general, embodiments of the present disclosure relate to methods and systems for performing pyrolysis of a feed gas, such as natural gas or a hydrocarbon gas, such as methane. Examples of these pyrolysis methods and examples of feed gas reactors that can be used for these pyrolysis processes are further described in detail in PCT Publication No. WO 2020 / 118417, which is incorporated herein by reference in its entirety.

[0035] In general, according to an embodiment of the present disclosure, a reaction chamber for a feedstock reactor is disclosed herein. The reaction chamber includes: a shell defining a reaction volume and including a heat-resistant refractory material; an inlet for allowing the feedstock to enter the reaction volume; an outlet for allowing the reaction products formed due to the decomposition of the feedstock in the reaction volume to leave the reaction volume; and a protective liner lining the inner surface of the shell. The protective liner includes a compliant shock-absorbing layer and may additionally include one or more heat-resistant layers. For example, the protective liner may include a first heat-resistant layer between the inner surface of the shell and the compliant shock-absorbing layer. The protective liner may include a second heat-resistant layer. The first heat-resistant layer may be positioned between the inner surface of the shell and the compliant shock-absorbing layer, and the compliant shock-absorbing layer may be positioned between the first heat-resistant layer and the second heat-resistant layer.

[0036] Embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings.

[0037] Figure 1 An embodiment of a feedstock reactor 100 for decomposing a feedstock according to an embodiment of the present disclosure is schematically illustrated.

[0038] The reactor 100 includes a reaction chamber 21 connected to a plurality of burners 18a-18d (which may be collectively referred to as burners 18). Each burner 18 includes a combustion chamber into which an oxidant 13a-13d (e.g., pure oxygen or air) and a fuel 15a-15d (e.g., unreacted raw material) are supplied. Each burner 18 also includes an igniter 11a-11a for triggering combustion of the fuel and the oxidant in the combustion chamber.

[0039] During the reaction cycle of the reactor 100, the feedstock 12 (e.g., hydrocarbon, such as methane) is supplied to the reaction chamber 21 under pressure. Similarly, the burners 18a-18d are filled with a combustible gas mixture including a mixture of fuel 15a-15d and oxidant 13a-13d. Once the reaction chamber 21 and the burner 18 have been loaded with the feedstock and the combustible gas mixture, respectively, the igniters 11a-11d are triggered, and the combustible gas mixture is caused to burn in the burner 18, which results in the generation of hot combustion products 17a-17d. The combustion products 17a-17d flow under pressure through the nozzles 16a-16d, which are connected to the burner 18 and extend into the internal volume of the reaction chamber 21. The combustion products 17a-17d are ejected from the nozzles 16a-16d and mixed with the feedstock in the reaction chamber 21.

[0040] As the combustion products 17a-17d flow into the reaction chamber 21, heat energy is transferred from the combustion products 17a-17d to the feedstock. The pressure within the reaction chamber 21 increases in response to the hot pressurized combustion products flowing into the reaction chamber 21, and thus energy is also transferred from the combustion products 17a-17d to the feedstock via the dynamic compression of the feedstock. Beyond a certain point, the increase in the temperature of the feedstock is sufficient to drive decomposition or pyrolysis of the feedstock. For example, in the case of methane, the decomposition takes the following form:

[0041] CH 4 + energy → C + 2H 2

[0042] The pyrolysis reaction produces a reaction product 14 that is extracted from the reaction chamber 21. A portion of the reaction product 14 is recycled back to the reaction chamber 21 for future reaction cycles. In the case of methane pyrolysis, the reaction product 14 may include one or more of hydrogen, nitrogen, and carbon, the undesirable products may primarily include carbon dioxide, nitrogen, and water, and the recycled gas mixture may primarily include unreacted natural gas, hydrogen, nitrogen, and carbon monoxide.

[0043] As described above, the reaction chamber 21 includes an outer shell that defines a reaction volume and includes a heat-resistant refractory material (eg, ceramic) and a protective liner that lines the outer shell and includes a compliant, shock-absorbing layer and optionally one or more heat-resistant layers.

[0044] According to some embodiments, the protective liner includes a first heat-resistant layer and a second heat-resistant layer, which can be metal layers each including a heat-resistant metal alloy (e.g., FeCr, TiZrMo) or a refractory metal (e.g., tungsten, molybdenum, tantalum, niobium, rhenium, or hafnium) or any combination thereof. Although the first heat-resistant layer can provide further heat resistance to the shell (in addition to the heat resistance provided by the heat-resistant refractory material), during the cyclic operation of the feed reactor 100 (i.e., due to repeated reaction cycles), the reaction chamber 21 is subjected to cyclic shock loading, which may damage the shell and potentially compromise the integrity of the reaction chamber 21. In order to provide a certain degree of protection against such shock loading, the protective liner includes a compliant shock-absorbing layer, which can help protect the shell from such shock loading during operation of the reactor 100. In particular, the compliant shock-absorbing layer can help prevent the shock pulse from cracking the fine heat-resistant refractory material included in the shell.

[0045] The compliant shock absorbing layer may additionally have heat resistant properties to allow it to withstand the high temperatures generated during pyrolysis. Further thermal protection may be provided by a second heat resistant layer, which together with the first heat resistant layer may sandwich the compliant shock absorbing layer. Furthermore, the compliant shock absorbing layer may be oxidation resistant (e.g., the compliant shock absorbing layer itself may be formed of one or more layers that provide oxidation resistance to the compliant shock absorbing layer).

[0046] According to some embodiments, the protective liner may include a compliant shock absorbing layer without a refractory layer. However, including a refractory layer between the compliant shock absorbing layer of the reaction chamber and the shell may help prevent the compliant shock absorbing layer from adhering to the refractory material of the shell during operation of the reactor.

[0047] Figure 2A is a schematic cross-sectional view of a reaction chamber 21 according to an embodiment of the present disclosure. The reaction chamber 21 includes a cylindrical housing 33, which includes one or more heat-resistant refractory materials (e.g., ceramics) to provide heat resistance to the reaction chamber 21 to resist the high temperatures generated during pyrolysis. A tapered end 35 (which also includes a heat-resistant refractory material) is provided at one end of the reaction chamber 21 adjacent to the cylindrical housing 33. A similar tapered end (not shown) is provided at the opposite end of the reaction chamber 21, also adjacent to the cylindrical housing 33.

[0048] Figure 2BAn example of a tapered metal heat-resistant layer 41 is shown that can be used to line the tapered end 35. A longitudinal slit 39 extends along the length of the metal heat-resistant layer 41 and is used to spring-load the metal heat-resistant layer 41 when a protective liner including the metal heat-resistant layer 41 is inserted into the tapered end 35 (as described in further detail below).

[0049] Figure 2C An example of a cylindrical first metal heat-resistant layer 32 that can be used to line a cylindrical housing 33 is shown. A longitudinal slit 31 extends along the length of the metal heat-resistant layer 32 and is used to spring-load the metal heat-resistant layer 32 when a protective liner including the metal heat-resistant layer 32 is inserted into the cylindrical housing 33 (as described in further detail below). A hole 37 is provided in the metal heat-resistant layer 32 for receiving the injection nozzle 16 (at Figure 1 Schematically shown in FIG.

[0050] Go to FIG. 3A to FIG. 3B , which shows various embodiments of a protective liner 30 for lining an outer shell 33 of a reaction chamber 21 .

[0051] Figure 3A FIG. 4 shows a cross section of the metal heat-resistant layer 32. Figure 2C As shown, the metal heat-resistant layer 32 includes longitudinal slits 31 extending along its length.

[0052] Figure 3B A cross section of a protective liner 30 is shown, which includes a metal heat resistant layer 32 and a compliant shock absorbing layer 34 lining the interior of the metal heat resistant layer 32. The compliant shock absorbing layer 34 also includes longitudinal slits 31 extending along its length and aligned with the longitudinal slits of the metal heat resistant layer 32.

[0053] Figure 3C A cross section of a protective liner 30 is shown, which includes a metal heat-resistant layer 32, a compliant shock-absorbing layer 34, and another cylindrical metal heat-resistant layer 36 lining the interior of the compliant shock-absorbing layer 34. The metal heat-resistant layer 36 also includes a longitudinal slit 31 extending along its length, which is aligned with the longitudinal slits of the compliant shock-absorbing layer 34 and the metal heat-resistant layer 32.

[0054] By first positioning the compliant shock absorbing layer 34 around the cylindrical metal heat resistant layer 32, and then positioning the cylindrical metal heat resistant layer 36 around the compliant shock absorbing layer 34, a Figure 3C Protective padding in.

[0055] Figure 4 An example of a compliant shock absorbing layer 24 is shown. The compliant shock absorbing layer 24 includes one or more suitable materials, such as ceramic fiber paper or FeCrAl mesh (eg, Figure 4FeCrAl meshes are generally highly resistant to oxidation and can be used continuously up to 1400°C. Examples of ceramic fiber papers that can be used include (https: / / www.unifrax.com / product / fiberfrax-felt-products) and (https: / / www.hb-specialalloy.com / fecral-alloys-introduction / ).

[0056] To line the outer shell 33 of the reaction chamber 21 with the protective liner 30, the protective liner 30 can be compressed / spring loaded by overlapping one edge of the protective liner 30 adjacent the longitudinal slit 31 with the other opposing edge (thereby compressing the tube). The protective liner 30 is then inserted into the reaction chamber 21 and then released to allow the protective liner 30 to be biased against the inner diameter of the outer shell 33. This spring-loaded installation can be achieved by providing a hole 37 ( Figure 2C ) and further reinforced to constrain the protective liner 30 relative to the housing 33. The protective liner 30 can be freely thermally grown as required and can be manufactured in sections to ensure that the tapered end 35 can be similarly lined and protected.

[0057] When used in conjunction with the terms "comprising" or "including" in the claims and / or the specification, the words "a" or "an" can mean "one", but are also consistent with the meaning of "one or more", "at least one", and "one or more than one", unless the content clearly indicates otherwise. Similarly, the word "another" can mean at least a second or more, unless the content clearly indicates otherwise.

[0058] As used herein, the terms "coupled," "coupled," or "connected" may have several different meanings, depending on the context in which the terms are used. For example, as used herein, the terms "coupled," "coupled," or "connected" may indicate that two elements or devices are directly connected to each other or are connected to each other via a mechanical element through one or more intermediate elements or devices, depending on the particular context. The term "and / or" herein, when used in conjunction with a list of items, means to include any one or more of the items in the list.

[0059] As used herein, reference to "about" or "approximately" a number, or "substantially" equal to a number means within + / - 10% of that number.

[0060] Language using such as "at least one of X, Y, and Z," "at least one of X, Y, or Z," "at least one or more of X, Y, and Z," "at least one or more of X, Y, and / or Z," or "at least one of X, Y, and / or Z" is intended to include both single items (e.g., only X, or only Y, or only Z) and multiple items (e.g., {X and Y}, {X and Z}, {Y and Z}, or {X, Y, and Z}). The phrase "at least one of" and similar phrases are not intended to express a requirement that every possible item must be present, although every possible item may be present.

[0061] Although the present disclosure has been described in conjunction with specific embodiments, it will be understood that the present disclosure is not limited to these embodiments and that those skilled in the art may make alterations, modifications and variations to these embodiments without departing from the scope of the present disclosure.

[0062] In addition, it is contemplated that any portion of any aspect or implementation discussed in this specification may be implemented or combined with any portion of any other aspect or implementation discussed in this specification.

Claims

1. A reaction chamber for a raw material reactor, comprising: a housing defining a reaction volume and comprising a heat-resistant refractory material; an inlet for admitting feedstock into the reaction volume; an outlet for allowing reaction products to exit the reaction volume, the reaction products being formed by decomposition of the feedstock in the reaction volume; and A protective liner lines the inner surface of the shell and includes a compliant shock absorbing layer.

2. The reaction chamber according to claim 1, wherein: The protective liner also includes a first heat-resistant layer.

3. The reaction chamber according to claim 2, wherein: The first heat resistant layer is positioned between an inner surface of the outer shell and the compliant shock absorbing layer.

4. The reaction chamber according to claim 1 or 2, wherein: The protective liner also includes a second heat-resistant layer.

5. The reaction chamber of claim 4, wherein: The first heat resistant layer is positioned between the inner surface of the outer shell and the compliant shock absorbing layer; and The compliant shock absorbing layer is positioned between the first heat resistant layer and the second heat resistant layer.

6. The reaction chamber according to any one of claims 1 to 5, wherein: The heat-resistant refractory material is ceramic.

7. The reaction chamber according to claim 2, wherein: The first heat-resistant layer includes metal.

8. The reaction chamber according to claim 7, wherein: The first heat-resistant layer includes one or more of the following: FeCr; TiZrMo; and a refractory metal.

9. The reaction chamber according to claim 4, wherein: The second heat-resistant layer includes metal.

10. The reaction chamber according to claim 9, wherein: The second heat-resistant layer includes one or more of the following: FeCr; TiZrMo; and a refractory metal.

11. The reaction chamber according to any one of claims 1 to 10, wherein: The compliant shock absorbing layer includes one or both of ceramic fiber paper and FeCrAl mesh.

12. A method for protecting a reaction chamber for a feedstock reactor, comprising: inserting a protective liner into the reaction chamber, wherein the protective liner includes a compliant shock absorbing layer; and The inner surface of the reaction chamber is lined with the protective liner.

13. The method according to claim 12, wherein: The protective liner also includes a first heat-resistant layer.

14. The method according to claim 13, wherein: The first heat-resistant layer and the compliant shock-absorbing layer are cylindrical; and The method also includes forming the protective liner by positioning the cylindrical compliant shock absorbing layer around a first cylindrical heat resistant layer prior to inserting the protective liner into the reaction chamber.

15. The method according to claim 14, wherein: Forming the protective pad also includes: A second cylindrical heat resistant layer is positioned around the cylindrical compliant shock absorbing layer.

16. The method according to claim 15, wherein: Forming the protective pad includes: Firstly positioning the cylindrical compliant shock absorbing layer around the second cylindrical heat resistant layer; and The first cylindrical heat resistant layer is then positioned around the cylindrical compliant shock absorbing layer.

17. The method according to any one of claims 12 to 16, wherein: The protective liner is resiliently biased such that after being inserted into the reaction chamber, the protective liner is biased to line an inner surface of the reaction chamber.

18. The method according to any one of claims 12 to 17, wherein: The protective pad includes a longitudinal opening extending from a first end of the protective pad to an opposing second end of the protective pad.

19. The method of claim 18, wherein: The longitudinal opening defines opposing first and second edges of the protective liner; and Inserting the protective liner into the reaction chamber includes spring loading the protective liner by overlapping a first edge and a second edge of the protective liner prior to inserting the protective liner into the reaction chamber.

20. The method according to any one of claims 12 to 19, wherein: The protective liner further includes one or more holes in the protective liner; and Lining the interior surface of the reaction chamber with the protective liner includes aligning the one or more apertures with one or more nozzles extending into the reaction chamber.

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