Oxidation reactor with specific geometry for partial oxidation of feed stream

Abstract

The present invention relates to an oxidation reactor for partial oxidation of a feed stream with an oxygen-containing oxidant stream to obtain a hydrogen-containing product stream. The invention also relates to the use of an oxidation reactor for the non-catalytic oxidation of a hydrocarbon-containing feed stream into a product stream containing hydrogen and carbon oxides, the use of an oxidation reactor for the autothermal reforming of a hydrocarbon-containing feed stream into a product stream containing hydrogen and carbon oxides, use of an oxidation reactor for partial oxidation of an ammonia-containing feed stream into a hydrogen and nitrogen-containing product stream, use of an oxidation reactor for autothermal reforming of an ammonia-containing feed stream into a hydrogen and nitrogen-containing product stream, a process for producing a hydrogen and carbon oxide-containing product stream from a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream, and a process for producing a product stream containing hydrogen and nitrogen from an ammonia-containing feed stream and an oxygen-containing oxidant stream.

Description

Technical Field

[0001] The present invention relates to an oxidation reactor for partially oxidizing a feed stream with an oxygen-containing oxidant stream to obtain a hydrogen-containing product stream. This partial oxidation can be carried out as a non-catalytic partial oxidation (POX) or as an autothermal reforming (ATR). Feed streams useful here include hydrocarbon-containing streams, but also ammonia-containing streams.

[0002] The invention also relates to a process for producing a crude synthesis gas stream from a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream by non-catalytic partial oxidation or autothermal reforming, and a process for producing a hydrogen- and nitrogen-containing product stream from an ammonia-containing feed / product stream and an oxygen-containing oxidant stream. The invention also relates to the corresponding use of the proposed oxidation reactor. Background Art

[0003] Synthesis gas is a gas mixture containing hydrogen and carbon oxides, which is used for various synthesis reactions. Examples are methanol synthesis, the production of ammonia by the Haber-Bosch process or the Fischer-Tropsch synthesis. Conventional routes for the production of hydrogen-containing synthesis gas include steam reforming, autothermal reforming (ATR) and non-catalytic partial oxidation (POX), in each case using a hydrocarbon feedstock as the reaction stream. ATR and POX are carried out in oxidation reactors of similar structure, the essential difference between these oxidation reactors being the presence of a catalyst layer in the lower part of the oxidation reactor in the autothermal reformer.

[0004] The partial oxidation of hydrocarbon feedstocks for the production of synthesis gas is usually carried out at high reactor temperatures of 1000° C. to 1500° C. and pressures of up to 100 bar. The oxidation reactor (POX reactor) for non-catalytic partial oxidation is usually a refractory lined reactor with a hemispherical or almost hemispherical dome. The partial oxidation burner (POX burner) is usually mounted on top of the dome, preferably at its axial pole / pole, for the introduction of the hydrocarbon feedstock, the oxygen-containing oxidant and optionally one or more moderator streams.

[0005] Industrial processes and apparatus for partial oxidation known in the prior art propose various apparatus for introducing and mixing the various streams, namely the hydrocarbonaceous feedstock, the oxidant, usually containing oxygen, and sometimes a moderator. The moderator used is usually carbon dioxide (CO 2 ) or steam, wherein the moderator is introduced into the reactor alone through a separate passage in the burner, or is introduced into the reactor mixed with one or more other feed streams upstream of the burner. The oxidant used is typically air, oxygen-enriched air or pure oxygen (containing at least 95 mol % oxygen). In one example, the hydrocarbon-containing feed stream is a stream containing hydrocarbons such as methane or higher hydrocarbons or other molecules containing hydrogen and carbon, such as alcohols such as methanol or ethanol. This can also be a stream from an upstream primary reformer, which contains not only carbon monoxide (CO), hydrogen (H 2 ), carbon dioxide (CO2 ) and water (H 2 O), and also hydrocarbons such as methane, ethane, ethylene, or higher hydrocarbons such as benzene, toluene or xylene. The hydrocarbon feedstock and the oxidant are usually mixed in the reactor in the vicinity of the injection nozzle.

[0006] The basic construction and use of oxidation reactors of the type mentioned are known per se from the literature and are described, for example, in the article “Gas Production”, Ullmann's Encyclopedia of Industrial Chemistry, 6th edition, electronic version 1998, Chapter 2.5 “Autothermal Catalytic Reforming” and Chapter 3 “Non-catalytic Partial Oxidation”. Both types of reactors have a reactor shell of rated / relevant pressure, which is usually made of a metallic material and is lined on the inside with one or more layers of refractory material, for example refractory bricks, which thus form a protective layer against the heat released inside the reactor and any corrosive gas components.

[0007] Another output stream for producing a hydrogen-containing gas proposed in recent literature is an ammonia-containing feed stream, which is reacted with an oxygen-containing oxidant stream and optionally a steam stream to obtain a hydrogen-containing product gas. This reaction can in turn be achieved, for example, by the principle of non-catalytic partial oxidation or by the principle of autothermal reforming in a correspondingly suitable oxidation reactor.

[0008] Oxidation reactors known from the prior art, in particular POX reactors or autothermal reformers, generally have an inlet region which is either designed in a conical or frustoconical manner on the one hand or in a dome-shaped manner on the other hand.

[0009] Each design has specific advantages and disadvantages:

[0010] - In the case of a dome-shaped inlet region, the transition from the small diameter to the large diameter can be achieved over a shorter length than in a (truncated) conical inlet region, which achieves a constant height and an equal diameter of the reactor, which allows oxidation reactors with relatively long cylindrical shell sections. This leads to improved mixing of the product gas in the axial direction and more options for the arrangement of the ATR catalyst.

[0011] - The dome-shaped inlet region offers greater flexibility in construction, since the dome can be adapted to a greater extent in terms of its geometry in the case of changes in reactor and burner diameters, whereas the (truncated) conical inlet region offers fewer degrees of freedom here, since it is not possible to deviate from the angular extreme of approximately 30° for structural or static reasons.

[0012] - The (truncated) conical inlet area ensures a greater distance between the burner flame and the inner wall of the oxidation reactor, which reduces thermal and mechanical stresses and wear on the refractory protective layer and to a lesser extent impairs the flame geometry, since recirculation zones and turbulences caused by the emergence of the jet near the inner wall of the oxidation reactor are avoided.

[0013] - A disadvantage of the dome-shaped inlet region is its limited diameter, since the absorption of the mechanical stresses generated by thermal expansion within the refractory covering in the inlet region becomes more complicated as the reactor diameter increases. The relatively large movements caused by thermal expansion and the increased mechanical stresses and forces on the refractory covering have a negative impact on the integrity and life of the refractory facing. Summary of the invention

[0014] It is therefore an object of the present invention to provide an oxidation reactor for partially oxidizing a feed stream with an oxygen-containing oxidant stream to obtain a hydrogen-containing product stream, which oxidation reactor does not have the above-mentioned disadvantages of the oxidation reactors known in the prior art and in which the specific advantages of the different designs are retained as much as possible.

[0015] This object is achieved in a first aspect of the invention by an oxidation reactor having the features of claim 1 .

[0016] In a further aspect, the object is achieved by using an oxidation reactor having the features of claims 11 to 14 .

[0017] In further aspects, the object is achieved by a method for producing a raw synthesis gas stream from a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream by non-catalytic partial oxidation according to claim 15 or by autothermal reforming according to claim 16, and by a method for producing a hydrogen- and nitrogen-containing product stream from an ammonia-containing feed / product stream and an oxygen-containing oxidant stream according to claim 17 or with the aid of autothermal reforming according to claim 18.

[0018] In a further aspect, the object is achieved by further configurations of the invention which are apparent from the dependent claims of the corresponding category.

[0019] Oxygen-containing oxidant refers to any oxygen-containing fluid, such as air, pure oxygen of any purity, or any other fluid capable of providing oxygen to the reactants.

[0020] A mechanism is an object which makes it possible to achieve a certain goal or contributes to the achievement of a certain goal. A mechanism for carrying out a particular method step is to be understood in particular to mean all physical objects that a person skilled in the art would consider for carrying out that method step. For example, a person skilled in the art would consider, based on his knowledge in the field, a mechanism for introducing or discharging a material flow to include all transport and delivery equipment that appears necessary or reasonable for carrying out that method step, i.e., for example, pipes, pumps, compressors, valves.

[0021] In the context of this specification, steam is a synonym for water vapor, unless otherwise specified in individual cases. In contrast, the term "water" refers to water in liquid form, unless otherwise specified in individual cases.

[0022] Where necessary, pressures are stated in absolute pressure units, referred to as bars (bara or bar(a)), or in gauge pressure units, referred to as barg or bar(g), unless otherwise stated in individual cases.

[0023] A fluid connection between two areas of an apparatus or system according to the invention refers to any type of connection that enables a fluid (e.g. a gas stream) to flow from one of the two areas to the other, ignoring intermediate areas or components. A direct fluid connection should in particular be considered to mean any type of connection that enables a fluid (e.g. a gas stream) to flow directly from one of the two areas to the other, without any other intermediate areas or components, except for pure transport operations and the mechanisms required therefor, such as pipes, valves, pumps, compressors, tanks. An example is a pipe that leads directly from one of the two areas to the other.

[0024] "Optionally" or "optionally" means that the subsequently described event or circumstance may or may not occur, or a feature may or may not exist. The description includes instances where the event or circumstance occurs and instances where it does not occur. The description also includes instances where the feature exists and instances where it does not exist.

[0025] The conditions for non-catalytic partial oxidation and autothermal reforming are known to the person skilled in the art from the prior art, for example from the literature discussed at the outset. These are physicochemical conditions under which a measurable, preferably industrially relevant, conversion of a fluid or fluidized carbonaceous feed stream into a synthesis gas product is achieved. As important parameters, these include the establishment of a suitable partial oxidation temperature, typically above about 1000° C. A particular feature of non-catalytic partial oxidation is the absence of a catalyst in the partial oxidation reactor. In contrast, a feature of autothermal reforming is the presence of a layer of a specific ATR catalyst in the lower part of the oxidation reactor, but such catalysts are known per se and are commercially available.

[0026] Those skilled in the art will make necessary adjustments to the conditions of non-catalytic partial oxidation and autothermal reforming according to routine experiments to adapt to their respective operating requirements. Any specific reaction conditions disclosed can be used as a guide, but should not be considered as limiting the scope of the invention.

[0027] The terms "inlet", "inlet", "outlet" and "outlet" relate to the flow direction of the feedstock through the oxidation reactor.

[0028] The invention is based on the finding that the disadvantages of oxidation reactors known to date from the prior art can be avoided if the inlet region of the oxidation reactor is constructed as a combination of a dome-shaped first section, preferably with a surface consisting of a part of a sphere, and a (truncated) conical second section, which merges into a cylindrical / cylindrical third section of the oxidation reactor. All three sections are connected to one another in a gas-tight manner and are provided on their inner sides with at least one fire-resistant protective layer. This makes it possible to combine the advantages of both constructions while overcoming their given application limitations for industrial-scale applications.

[0029] The dome-shaped structure of the inlet region remains constant over the entire performance / size range of the oxidation reactor.The burners are arranged at the axial pole of the dome-shaped inlet region.

[0030] The (truncated)conical inlet area is configured with a defined inclination angle. In case the diameter / height ratio of the oxidation reactor is fixed, only the length of the truncated cone and the diameter of the cylindrical section have to be adjusted for its scale-up.

[0031] Due to the combination of the dome-shaped inlet area with the (truncated) conical inlet area, the inclination angle of the cone or truncated cone can be kept much smaller than in constructions according to the prior art, which increases the volume of the reactor while minimizing the forces and stresses on the refractory protective layer.

[0032] Preferred embodiments of the present invention

[0033] The second aspect of the invention is characterized in that the first section (a1) is a hemispherical structure, ie having a constant radius corresponding to a semicircle in the longitudinal direction of the oxidation reactor. This geometry exerts minimal loads and forces on the refractory lining.

[0034] The third aspect of the present invention is characterized in that the truncated cone-shaped second section (a2) has an inclination angle relative to the longitudinal axis, which is in the range of 5° to 30° (including the end values), preferably in the range of 10° to 20° (including the end values), wherein the mentioned end values ​​are included in the range of values. Studies have shown that due to the small inclination angles of the truncated cone in the case of the configuration of the oxidation reactor according to the prior art, the volume of the reactor can be increased, while the forces and loads on the refractory protective layer can be minimized.

[0035] The fourth aspect of the invention is characterized in that the frustoconical second section (a2) has an inner diameter D1 at its narrow end and an inner diameter D2 at its wide end, wherein the ratio D1 / D2 is in the range of 0.7 to 0.9, preferably in the range of 0.75 to 0.85. Studies have shown that these length ratios provide particular benefits.

[0036] The fifth aspect of the invention is characterized in that the slope of the dome-shaped first section corresponds to the slope of the frustoconical second section at the transition point between sections (a1) and (a2). In this way, apexes are avoided in the reactor shell and the internal refractory protective layer, which increases the mechanical stability of the device and minimizes thermal stresses at the junction of sections (a1) and (a2).

[0037] A sixth aspect of the invention is characterized in that the reactor housing is surrounded by at least one cooling zone or cooling housing, by means of which at least one section of the reactor housing can be cooled by a fluid cooling medium. In this way, the control of the temperature of the oxidation reactor is improved and the structural materials and components used in the oxidation reactor are subject to lower thermal stresses.

[0038] A seventh aspect of the invention is characterized in that there are at least two cooling zones arranged along the longitudinal axis of the oxidation reactor. As a result, the operation of the oxidation reactor can continue if, for example, only a certain point of the reactor shell has to be inspected or repaired. In this case, only the cooling zone around the affected point in the reactor shell is taken out of operation and then disassembled. After the inspection or repair is completed, the cooling zone is reassembled and put back into operation. The operation of the oxidation reactor can continue for the entire duration of the inspection or repair measures, thereby avoiding production downtime.

[0039] It is also advantageous that the presence of two or more cooling zones of the invention, for example two or more cooling zones arranged over the length of the oxidation reactor, enables a better / more refined reaction to the different heat generated along the longitudinal axis of the oxidation reactor. For example, in the illustrative configuration of the oxidation reactor as an ATR, it is possible to differentiate the heat budget in the upper burner part of the oxidation reactor from the heat budget in the lower reactor part containing the ATR catalyst bed. With the inventive configuration of the oxidation reactor with multiple cooling zones, a better / more refined reaction to this difference is possible, so that the result is an improved temperature control of the oxidation reactor.

[0040] The eighth aspect of the present invention is characterized in that a common cooling medium flows through the at least two cooling zones, preferably water is used as the common cooling medium. Water has sufficient volume and quality in most places, is non-toxic, and has advantages if cooling is performed in the form of evaporative cooling in a specific cooling zone. The use of a common cooling medium additionally simplifies the construction of the coolant circuit.

[0041] The ninth aspect of the invention is characterized in that the at least two cooling zones can each be operated separately and can each be assembled and disassembled separately. As a result, in one example, if, for example, only a check or repair is required at a specific point of the reactor housing, the operation of the oxidation reactor can continue. The operation of the oxidation reactor can continue for the duration of the check or repair measure, thereby avoiding production downtime.

[0042] A tenth aspect of the present invention is characterized in that a portion of the reaction chamber is filled with a bed of solid particulate catalyst active in autothermal reforming (ATR).

[0043] An eleventh aspect of the invention relates to the use of an oxidation reactor according to claims 1 to 9 for the non-catalytic partial oxidation (POX) of a hydrocarbon-containing feed stream to a product stream comprising hydrogen and carbon oxides.

[0044] A twelfth aspect of the invention relates to the use of an oxidation reactor according to claim 10 for the autothermal reforming (ATR) of a hydrocarbon-containing feed stream into a product stream containing hydrogen and carbon oxides.

[0045] A thirteenth aspect of the invention relates to the use of an oxidation reactor according to claims 1 to 9 for the non-catalytic partial oxidation of an ammonia-containing feed stream to form a product stream comprising hydrogen and nitrogen.

[0046] A fourteenth aspect of the invention relates to the use of an oxidation reactor according to claim 10 for autothermal reforming of an ammonia-containing feed stream into a product stream containing hydrogen and nitrogen.

[0047] A fifteenth aspect of the present invention relates to a method for producing a product stream containing hydrogen and carbon oxides from a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream by non-catalytic partial oxidation, the method comprising the steps of:

[0048] (a) providing an oxidation reactor according to claims 1 to 9;

[0049] (b) introducing a hydrocarbon-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner;

[0050] (c) reforming a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream in said burner and / or in said reaction chamber under conditions for non-catalytic partial oxidation (POX);

[0051] (d) discharging the product stream comprising hydrogen and carbon oxides through an outlet.

[0052] A sixteenth aspect of the present invention relates to a method for producing a product stream containing hydrogen and carbon oxides from a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream by autothermal reforming, the method comprising the steps of:

[0053] (a) providing an oxidation reactor according to claim 10;

[0054] (b) introducing a hydrocarbon-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner;

[0055] (c) reforming a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream in the burner and / or in the reaction chamber and / or in a catalyst bed under conditions for autothermal reforming (ATR);

[0056] (d) discharging the product stream comprising hydrogen and carbon oxides through an outlet.

[0057] A seventeenth aspect of the present invention relates to a method for producing a product stream containing hydrogen and nitrogen from an ammonia-containing feed stream and an oxygen-containing oxidant stream by non-catalytic partial oxidation, the method comprising the steps of:

[0058] (a) providing an oxidation reactor according to claims 1 to 9;

[0059] (b) introducing an ammonia-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner;

[0060] (c) converting an ammonia-containing feed stream and an oxygen-containing oxidant stream in said burner and / or in said reaction chamber under conditions for non-catalytic partial oxidation of ammonia;

[0061] (d) discharging the product stream comprising hydrogen and nitrogen via an outlet.

[0062] An eighteenth aspect of the present invention relates to a method for producing a product stream containing hydrogen and nitrogen from an ammonia-containing feed stream and an oxygen-containing oxidant stream by autothermal reforming, the method comprising the steps of:

[0063] (a) providing an oxidation reactor according to claim 10;

[0064] (b) introducing an ammonia-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner;

[0065] (c) converting an ammonia-containing feed stream and an oxygen-containing oxidant stream in the burner and / or in the reaction chamber and / or in a catalyst bed under conditions for autothermal reforming (ATR);

[0066] (d) discharging the product stream comprising hydrogen and nitrogen via an outlet.

[0067] Working Example

[0068] Further developments, advantages and possible uses of the invention will also become apparent from the following description of working examples and from the accompanying drawings. The invention is formed by all the features described and / or depicted which may form the invention alone or in any combination, regardless of how they are combined in the claims or in the dependent references therein. BRIEF DESCRIPTION OF THE DRAWINGS

[0069] Figure 1 is a schematic diagram of a first configuration of an oxidation reactor as a POX reactor according to the prior art;

[0070] Figure 2 is a schematic diagram of a second configuration of an oxidation reactor as an ATR according to the prior art;

[0071] Figure 3 is a schematic diagram of a third configuration of an oxidation reactor as a POX reactor according to the present invention;

[0072] Figure 4 is a schematic diagram of a fourth configuration of an oxidation reactor as an ATR according to the present invention.

[0073] Hereinafter, "not shown" means that the element in the figure in question is not graphically represented, but is still present. DETAILED DESCRIPTION

[0074] Figure 1 A schematic diagram of a first configuration of an oxidation reactor 1 as a POX reactor according to the prior art for partial oxidation of a feed stream with an oxygen-containing oxidant stream to obtain a hydrogen-containing product stream is shown. The oxidation reactor comprises in its upper part a frustoconical reactor shell 10 which merges further downwards into a cylindrical section.

[0075] An inlet for a feed stream is installed at the inlet end of the reactor shell 10, wherein the inlet is configured as a burner 40, the feed stream is introduced into the empty volume 30 through the burner via a pipe 2, and the oxygen-containing oxidant stream is introduced into the empty volume 30 through the burner via a pipe 3, the empty volume is arranged inside the reactor of the oxidation reactor 1 and serves as a reaction chamber. In this case, a burner flame 50 is formed. Optionally, a moderator stream containing steam and / or carbon dioxide can be introduced into the oxidation reactor via a pipe 2 or a pipe 3 or a separate pipe not shown, or a combination of at least two of these pipes. In the reaction chamber, the feed stream reacts with the oxygen-containing oxidant stream under non-catalytic partial oxidation (POX) conditions. The product stream formed here is discharged from the oxidation reactor 1 via an outlet 4 installed at the outlet end of the reactor shell 10. All described components of the oxidation reactor 1 are connected to each other in a gas-tight manner and are fluidically connected.

[0076] Figure 2 A schematic diagram of a second configuration of an oxidation reactor as an autothermal reformer according to the prior art is shown. Unless otherwise indicated in the context, the same reference numerals denote elements having the same function and structure in the oxidation reactor shown in the figure. Basically, Figure 2 , 3 and the construction shown in 4 corresponds to the combination Figure 1 The constructions described are as follows; the differences will be pointed out respectively.

[0077] Figure 2 The construction of the oxidation reactor 1 shown as an ATR corresponds largely to Figure 1 The configuration shown differs in that the ATR catalyst bed 60 is now arranged in the lower part of the reaction chamber 30. For operation of the oxidation reactor as an autothermal reformer, and an oxygen-containing oxidant, steam is introduced into the oxidation reactor via line 2 or line 3 or a separate line not shown, or a combination of at least two of these lines.

[0078] according to Figure 1 and Figure 2 The respective advantages and disadvantages of the reactor of the prior art shown have already been explained above.

[0079] Figure 3 A schematic diagram of a third configuration of an oxidation reactor according to the present invention as a POX reactor is shown. The pressure-rated reactor housing 10 is made of a metal material and comprises the following sections arranged along the longitudinal axis:

[0080] (a1) a dome-shaped first section 12, which preferably has a surface consisting of a part of a sphere;

[0081] (a2) a frustoconical second section 14 having an inner diameter D1 at its narrow end and an inner diameter D2 at its wide end;

[0082] (a3) a cylindrical / cylindrical third section 16,

[0083] The section (a1) is connected to the section (a2) in an airtight manner, and the section (a2) is connected to the section (a3) ​​in an airtight manner.

[0084] A protective layer 20 made of a fire-resistant and corrosion-resistant material is installed inside the reactor housing 10. Within the protective layer there is a void volume 30 which serves as a reaction chamber.

[0085] An inlet for a feed stream is installed at the axial pole of the first section (a1), wherein the inlet is configured as a burner 40, the feed stream is introduced into the reaction chamber through the burner via a pipe 2, and the oxygen-containing oxidant is introduced into the reaction chamber through the burner via a pipe 3. For clarity, the burner flame is not shown in the figure. Optionally, a moderator stream containing steam and / or carbon dioxide can be introduced into the oxidation reactor via a pipe 2 or a pipe 3 or a separate pipe not shown, or a combination of at least two of these pipes. In the reaction chamber, the feed stream reacts with the oxygen-containing oxidant stream under non-catalytic partial oxidation (POX) conditions. The product stream formed here is discharged from the oxidation reactor 1 via an outlet 4 installed at the outlet end of the reactor housing 10. All described components of the oxidation reactor 1 are connected to each other in a gas-tight manner and in a fluid connection.

[0086] Figure 4 A schematic diagram of a third configuration of an oxidation reactor according to the invention is shown (autothermal reformer). Figure 4 The construction of the oxidation reactor 1 shown as an ATR corresponds largely to Figure 3 The configuration shown differs in that the ATR catalyst bed 60 is now arranged in the lower part of the reaction chamber 30. For operation of the oxidation reactor as an autothermal reformer, and an oxygen-containing oxidant, steam is introduced into the oxidation reactor via line 2 or line 3 or a separate line not shown, or a combination of at least two of these lines.

[0087] In other embodiments, Figure 3 and 4 In the oxidation reactor shown, the first section (a1) is a hemispherical structure (not shown). This geometry imposes minimal loads and forces on the refractory lining.

[0088] In other embodiments, Figure 3 and 4In the oxidation reactor shown, the truncated cone-shaped second section (a2) has an inclination angle relative to the longitudinal axis, which is in the range of 5° to 30° (inclusive), preferably in the range of 10° to 20° (inclusive), wherein the mentioned end values ​​are included in the numerical range (not shown). Studies have shown that due to these inclination angles of the truncated cone, the volume of the reactor is increased, while at the same time, the forces and loads on the refractory protective layer can be minimized.

[0089] In other embodiments, Figure 3 and 4 In the oxidation reactor shown, the frustoconical second section (a2) has an inner diameter D1 at its narrow end and an inner diameter D2 at its wide end, wherein the ratio D1 / D2 is in the range of 0.7 to 0.9, preferably in the range of 0.75 to 0.85 (not shown). Studies have shown that these length ratios provide particular benefits.

[0090] In other embodiments, Figure 3 and 4 In the oxidation reactor shown, the slope of the dome-shaped first section corresponds to the slope of the frustoconical second section at the transition point between sections (a1) and (a2) (not shown). In this way, vertices are avoided in the reactor shell and the internal refractory protective layer, which increases the mechanical stability of the device and minimizes thermal stresses at the junction of sections (a1) and (a2).

[0091] In other embodiments, Figure 3 and 4 In the oxidation reactor shown, the reactor shell is surrounded by at least one cooling zone, by means of which at least one section of the reactor shell can be cooled by a fluid cooling medium (not shown). In this way, the control of the temperature of the oxidation reactor is improved and the structural materials and components used in the oxidation reactor are subjected to lower thermal stresses.

[0092] In other embodiments, Figure 3 and 4 In the oxidation reactor shown, there are at least two cooling zones (not shown) arranged along the longitudinal axis of the oxidation reactor. As a result, the operation of the oxidation reactor can continue if, for example, only a certain point of the reactor shell needs to be inspected or repaired. In this case, only the cooling zone around the affected point in the reactor shell is taken out of operation and then disassembled. After the inspection or repair is completed, this cooling zone is reassembled and put back into operation. The operation of the oxidation reactor can continue for the entire duration of the inspection or repair measure, thereby avoiding production downtime.

[0093] In other embodiments, Figure 3 and4 In the oxidation reactor shown, a common cooling medium is used which flows through all cooling zones (not shown), preferably water. Water is available in sufficient volume and quality in most places, is non-toxic, and has advantages if cooling is carried out in the form of evaporative cooling in a specific cooling zone. The use of a common cooling medium additionally simplifies the construction of the coolant circuit.

[0094] In other embodiments, Figure 3 and 4 In the oxidation reactor shown, the at least two cooling zones are each independently operable / operable and can be assembled and disassembled individually. As a result, in one embodiment, the operation of the oxidation reactor can continue if, for example, only a check or repair is required at a specific point of the reactor housing. The operation of the oxidation reactor can be continued for the entire duration of the check or repair measure, thereby avoiding production downtime.

[0095] In other embodiments, Figure 3 The oxidation reactor shown is used for the non-catalytic partial oxidation (POX) of a hydrocarbon-containing feed stream to a product stream containing hydrogen and carbon oxides.

[0096] In other embodiments, Figure 3 The oxidation reactor shown is used to partially oxidize an ammonia-containing feed stream to form a product stream containing hydrogen and nitrogen.

[0097] In another embodiment, Figure 4 The oxidation reactor shown is used for autothermal reforming (ATR) of a hydrocarbon-containing feed stream into a product stream containing hydrogen and carbon oxides.

[0098] In another embodiment, Figure 4 The oxidation reactor shown is used for autothermal reforming (ATR) of an ammonia-containing feed stream into a product stream containing hydrogen and nitrogen.

[0099] Additional working embodiments of the present invention include a method for producing a product stream containing hydrogen and carbon oxides from a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream, the method comprising the steps of:

[0100] (a) providing an oxidation reactor according to claims 1 to 9;

[0101] (b) introducing a hydrocarbon-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner;

[0102] (c) reforming a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream in said burner and / or in said reaction chamber under conditions for non-catalytic partial oxidation (POX);

[0103] (d) discharging the product stream comprising hydrogen and carbon oxides through an outlet.

[0104] Additional working embodiments of the present invention include a method for producing a product stream containing hydrogen and carbon oxides from a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream, the method comprising the steps of:

[0105] (a) providing an oxidation reactor according to claim 10;

[0106] (b) introducing a hydrocarbon-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner;

[0107] (c) reforming a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream in the burner and / or in the reaction chamber and / or in a catalyst bed under conditions for autothermal reforming (ATR);

[0108] (d) discharging the product stream comprising hydrogen and carbon oxides through an outlet.

[0109] Additional working embodiments of the present invention include a method for producing a product stream containing hydrogen and nitrogen from an ammonia-containing feed stream and an oxygen-containing oxidant stream, the method comprising the steps of:

[0110] (a) providing an oxidation reactor according to claims 1 to 9;

[0111] (b) introducing an ammonia-containing feed stream, an oxygen-containing oxidant stream and optionally a moderator stream into a reaction chamber via a burner, and optionally introducing a steam stream into the reaction chamber;

[0112] (c) subjecting an ammonia-containing feed stream and an oxygen-containing oxidant stream to reforming in said burner and / or in said reaction chamber under conditions for non-catalytic partial oxidation of ammonia;

[0113] (d) discharging the product stream comprising hydrogen and nitrogen via an outlet.

[0114] Additional working embodiments of the present invention include a method for producing a product stream containing hydrogen and nitrogen from an ammonia-containing feed stream and an oxygen-containing oxidant stream, the method comprising the steps of:

[0115] (a) providing an oxidation reactor according to claim 10;

[0116] (b) introducing an ammonia-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner;

[0117] (c) converting an ammonia-containing feed stream and an oxygen-containing oxidant stream in the burner and / or in the reaction chamber and / or in a catalyst bed under conditions for autothermal reforming (ATR);

[0118] (d) discharging the product stream comprising hydrogen and nitrogen via an outlet.

[0119] Without departing from the scope of the present disclosure as defined by the appended claims, changes to the above-described embodiments or configurations of the present disclosure are possible. Expressions such as "comprises," "comprising," "containing," "having," and "is" used in the specification and claims of the present disclosure should be considered non-exclusive, meaning that they allow for the presence of objects, components, or elements that are not explicitly described. In certain cases, if there is no clear indication to the contrary, the singular (one / a kind) should also be considered to refer to the plural.

[0120] Reference numerals list

[0121] [1] Oxidation reactor

[0122] [2] Pipeline

[0123] [3] Pipeline

[0124] [4] Export

[0125]

[10] Reactor housing, cylindrical third section

[0126]

[12] Reactor housing, dome-shaped first section

[0127]

[14] Reactor housing, frustoconical second section

[0128]

[16] Reactor housing, cylindrical third section

[0129]

[20] Protective layer (refractory lining)

[0130]

[30] Empty volume (reaction chamber)

[0131]

[40] Burner

[0132]

[50] Burner flame

[0133]

[60] ATR catalyst bed

Claims

1. An oxidation reactor for partially oxidizing a feed stream with an oxygen-containing oxidant stream to obtain a hydrogen-containing product stream, the oxidation reactor comprising: (a) A pressure-rated reactor housing having a longitudinal axis and constructed of a metallic material, wherein the reactor housing comprises the following sections arranged along the longitudinal axis: (a1) a dome-shaped first section, which preferably has a surface consisting of a part of a sphere, (a2) The second section of (truncated) cone, (a3) a third cylindrical section, wherein the first section (a1) is airtightly connected to the second section (a2), and the second section (a2) is airtightly connected to the third section (a3); (b) at least one protective layer of fire-resistant and corrosion-resistant material installed in the reactor shell; (c) a void volume disposed within the protective layer, the void volume serving as a reaction chamber; (d) an inlet for a feed stream mounted at an axial pole of the first section (a1), wherein the inlet is configured as a burner, through which a feed stream, an oxygen-containing oxidant stream and an optional moderator stream can be introduced into the reaction chamber; (e) an outlet disposed at the outlet end of the reactor housing through which a product stream can be discharged.

2. The oxidation reactor according to claim 1, characterized in that The first section (a1) is a hemispherical structure.

3. The oxidation reactor according to claim 1 or 2, characterized in that: The frustoconical second section (a2) has an inclination angle relative to the longitudinal axis, the inclination angle being in the range of 5° to 30° and including end values, preferably, the inclination angle is in the range of 10° to 20° and including end values.

4. An oxidation reactor according to any one of the preceding claims, characterized in that The frustoconical second section (a2) has an inner diameter D1 at its narrow end and an inner diameter D2 at its wide end, wherein the ratio D1 / D2 is in the range of 0.7 to 0.9, preferably in the range of 0.75 to 0.

85.

5. An oxidation reactor according to any one of the preceding claims, characterized in that The slope of the dome-shaped first section corresponds to the slope of the frustoconical second section at the transition point between the first section (a1) and the second section (a2).

6. An oxidation reactor according to any one of the preceding claims, characterized in that The reactor shell is surrounded by at least one cooling zone, by means of which at least one section of the reactor shell can be cooled by means of a fluid cooling medium.

7. An oxidation reactor according to any one of the preceding claims, characterized in that There are at least two cooling zones disposed along the longitudinal axis of the oxidation reactor.

8. The oxidation reactor according to claim 7, characterized in that A common cooling medium flows through the at least two cooling zones, and water is preferably used as the common cooling medium.

9. The oxidation reactor according to claim 7, characterized in that The at least two cooling zones are each independently operable and can be each independently assembled and disassembled.

10. An oxidation reactor according to any one of the preceding claims, characterized in that A portion of the reaction chamber is filled with a bed of solid particulate catalyst active in autothermal reforming.

11. Use of an oxidation reactor according to claims 1 to 9 for the non-catalytic partial oxidation of a hydrocarbon-containing feed stream to a product stream containing hydrogen and carbon oxides.

12. Use of an oxidation reactor according to claim 10 for autothermal reforming of a hydrocarbon-containing feed stream into a product stream containing hydrogen and carbon oxides.

13. Use of an oxidation reactor according to claims 1 to 9 for the partial oxidation of an ammonia-containing feed stream to form a product stream containing hydrogen and nitrogen.

14. Use of an oxidation reactor according to claim 10 for autothermal reforming of an ammonia-containing feed stream into a product stream containing hydrogen and nitrogen.

15. A method for producing a product stream containing hydrogen and carbon oxides from a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream, the method comprising the steps of: (a) providing an oxidation reactor according to claims 1 to 9; (b) introducing a hydrocarbon-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner; (c) converting a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream in said burner and / or in said reaction chamber under conditions for non-catalytic partial oxidation; (d) discharging the product stream comprising hydrogen and carbon oxides through an outlet.

16. A method for producing a product stream containing hydrogen and carbon oxides from a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream, the method comprising the steps of: (a) providing an oxidation reactor according to claim 10; (b) introducing a hydrocarbon-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner; (c) converting a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream in the burner and / or in the reaction chamber and / or in a catalyst bed under conditions for autothermal reforming; (d) discharging the product stream comprising hydrogen and carbon oxides through an outlet.

17. A method for producing a product stream containing hydrogen and nitrogen from an ammonia-containing feed stream and an oxygen-containing oxidant stream, the method comprising the steps of: (a) providing an oxidation reactor according to claims 1 to 9; (b) introducing an ammonia-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner; (c) subjecting an ammonia-containing feed stream and an oxygen-containing oxidant stream to reforming in said burner and / or in said reaction chamber under conditions for non-catalytic partial oxidation of ammonia; (d) discharging the product stream comprising hydrogen and nitrogen via an outlet.

18. A method for producing a product stream containing hydrogen and nitrogen from an ammonia-containing feed stream and an oxygen-containing oxidant stream, the method comprising the steps of: (a) providing an oxidation reactor according to claim 10; (b) introducing an ammonia-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner; (c) converting an ammonia-containing feed stream and an oxygen-containing oxidant stream in the burner and / or in the reaction chamber and / or in a catalyst bed under conditions for autothermal reforming; (d) discharging the product stream comprising hydrogen and nitrogen via an outlet.

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