Oxidation reactor for partial oxidation of feed stream

Abstract

The 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, equipped with a plurality of cooling zones surrounding the reactor housing. Operations of the oxidation reactor may be continued if, for example, only inspection or repair needs to be performed at a specific point of the reactor housing. 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 the partial oxidation 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 hydrogen and nitrogen-containing product stream 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 product stream containing hydrogen and nitrogen from an ammonia-containing feed stream and an oxygen-containing oxidant stream. 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 for the introduction of the hydrocarbon feedstock, the oxygen-containing oxidant and optionally one or more moderator streams.

[0005] Industrial methods and apparatus for partial oxidation known in the prior art propose various apparatus for introducing and mixing various streams, namely hydrocarbon feedstock, an oxidant usually containing oxygen and sometimes a moderator. The moderator used is usually carbon dioxide (CO2) 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 usually air, oxygen-enriched air or pure oxygen (containing at least 95 mol % of oxygen). The hydrocarbon feed stream is a stream containing hydrocarbons such as methane or higher hydrocarbons or other molecules containing hydrogen and carbon (e.g., alcohols such as methanol, ethanol). This can also be a stream from an upstream primary reformer, which contains not only carbon monoxide (CO), hydrogen (H2), CO2 and water (H2O), but 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 at a position close to 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 pressure-rated reactor shell, 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 of the specified type are usually cooled externally in order to extend the service life of the construction materials used for the oxidation reactor and in order to improve energy recovery. For this purpose, the oxidation reactor is surrounded by a cooling shell through which a fluid cooling medium flows, which is usually pressurized water. For this purpose, the cooling medium is introduced into the cooling shell in cold form, absorbs part of the reaction enthalpy released in the reactor, and is discharged from the cooling shell in hot form. The heated cooling medium is then cooled by means of one or more coolers and is led back into the cooling shell in cooled form, thus forming a cooling medium circuit. The heat extracted from the cooling medium heated during the cooling process can be recovered by indirect heat exchange.

[0009] A disadvantage of the procedure described is that, with the methods of construction of oxidation reactors customary to date, their operation, even for a short period of time, is essentially only possible when the cooling system is in operation. This means that if the cooling system fails, the oxidation reactor must be completely shut down, or that the cooling housing must be disassembled in order to carry out maintenance or inspection work outside the reactor housing. This leads to increased costs due to the corresponding stoppage of production in the oxidation reactor. Summary of the invention

[0010] It is therefore an object of the present invention to provide an oxidation reactor for the partial oxidation of a feed stream with an oxygen-containing oxidant stream to obtain a hydrogen-containing product stream which does not have the above-mentioned disadvantages of the oxidation reactors known from the prior art.

[0011] This object is achieved in a first aspect of the invention by an oxidation reactor having the features of claim 1 .

[0012] In further aspects, this object is achieved by using an oxidation reactor having the features of claims 17 to 19 .

[0013] In further aspects, the object is achieved by a method for producing a crude synthesis gas stream from a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream by non-catalytic partial oxidation according to claim 20 or by autothermal reforming according to claim 21, and by a method for producing a hydrogen- and nitrogen-containing product stream from an ammonia-containing feed stream and an oxygen-containing oxidant stream according to claim 22.

[0014] 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.

[0015] 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 carbon-containing reactants.

[0016] 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.

[0017] 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.

[0018] 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.

[0019] 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.

[0020] "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.

[0021] 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.

[0022] 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.

[0023] In order to avoid cracks due to thermal circumferential expansion of the protective layer, in the case of a multilayer lining of an oxidation reactor with refractory bricks, empty spaces in the form of annular gaps are usually provided between the different protective layers or between the protective layer and the reactor shell (expansion gaps in the form of annular gaps), which provide sufficient space for radial thermal expansion. Alternatively or additionally, periodic expansion joints / joints can be provided in each brick layer (periodic circumferential expansion gaps) and / or between the brick layers (expansion gaps in the longitudinal direction). A combination of periodic circumferential expansion gaps, longitudinal expansion gaps and expansion gaps in the form of annular gaps is also possible.

[0024] The terms "inlet", "inlet", "outlet" and "outlet" relate to the flow direction of the feedstock through the oxidation reactor.

[0025] The invention is based on the finding that the disadvantages of oxidation reactors known hitherto from the prior art can be avoided if the oxidation reactor is equipped with a plurality of cooling zones around the reactor housing. As a result, the operation of the oxidation reactor can continue if, for example, only a check or repair has to be carried out at a specific point of the reactor housing. In this case, only the cooling zone around the affected point in the reactor housing is taken out of operation and then disassembled. After the inspection or repair has been 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 downtimes.

[0026] 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.

[0027] Preferred embodiments of the present invention

[0028] The second aspect of the invention is characterized in that the first cooling zone and the second cooling zone 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.

[0029] A third aspect of the invention is characterized in that the flow of cooling medium through the first cooling zone and the second cooling zone is individually controllable. In this way, a better / more refined response to local differences in the thermal budget of the oxidation reactor is possible, so that as a result an improved temperature control of the oxidation reactor is achieved.

[0030] A fourth aspect of the invention is characterized in that the pressure of the cooling medium in the first cooling zone and in the second cooling zone is individually controllable. In this way, a better / more refined reaction to local differences in the thermal budget of the oxidation reactor is also possible, so that the result is an improved temperature control of the oxidation reactor. For example, one cooling zone can be operated with a boiling cooling medium, which leads to a particularly intensive heat transfer, while the cooling medium in the other cooling zone remains as a single-phase fluid.

[0031] A fifth aspect of the present invention is characterized by using common first and second fluid cooling media, which flow through the first cooling zone and the second cooling zone. Using a common cooling medium simplifies the construction of the coolant circuit.

[0032] The sixth aspect of the present invention is characterized in that the first cooling zone and the second cooling zone are fluidly connected, and the mass flow of the cooling medium through the first cooling zone and the second cooling zone is independently controllable. This configuration combines the advantages of simplifying the coolant circuit and improving the temperature control of the oxidation reactor.

[0033] The seventh aspect of the present invention is characterized in that a cooling device for intermediate cooling of the cooling medium is present between the first cooling zone and the second cooling zone. This configuration is advantageous when the cooling medium in the two cooling zones is kept as a single-phase fluid, but a large amount of heat still needs to be removed from the first cooling zone.

[0034] An eighth aspect of the invention is characterized in that there are more than two cooling zones. Although this configuration increases the complexity of the structure, in this way it is possible to react better / more delicately to local differences in the thermal budget of the oxidation reactor, so that the temperature control of the oxidation reactor is improved as a result.

[0035] A ninth aspect of the invention is characterized in that a common cooling medium is used which flows through all cooling zones, wherein water is preferably 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.

[0036] The tenth aspect of the present invention is characterized in that the inlet end is a frustoconical structure, which is gas-tightly connected to the burner at its narrow end and gas-tightly connected to the reactor housing at its wide end.

[0037] The eleventh aspect of the invention is characterized in that the thermal conductivity of the first protective layer is lower than the thermal conductivity of the second protective layer. The advantage of this configuration is the reduced effect of the lower thermal conductivity of the first protective layer on the heating of the reactor shell, especially when one or more cooling zones are not in operation.

[0038] The twelfth aspect of the present invention is characterized in that there are a plurality of expansion gaps in the first and / or second protective layer, and preferably, the plurality of expansion gaps are evenly distributed along the circumference and / or length of the first and / or second protective layer. In this way, damage to the protective layer due to thermal expansion is avoided.

[0039] The thirteenth aspect of the present invention is characterized in that the expansion gap in the form of an annular gap is arranged between the reactor shell and the first protective layer and / or between the first protective layer and the second protective layer. In this way, damage to the protective layer due to thermal expansion is avoided.

[0040] A fourteenth aspect of the invention is characterized in that the wall thickness and / or thermal conductivity of the first and second protective layers are selected so that, without the passage of a cooling medium through one or more cooling zones, the temperature of the reactor shell at its outer surface is in the range of 180° C. to 300° C., preferably in the range of 200° C. to 250° C. These specified temperatures are advantageous because energy consumption, material stress and thermal exposure of operating personnel are reduced.

[0041] A fifteenth aspect of the invention is characterized in that water is used as common cooling medium, and the wall thickness and thermal conductivity of the first and second protective layers and the mass flow rate of the common cooling medium through the cooling zones are selected so that the temperature of the cooling medium discharged from the cooling zones is below 100° C. This limited temperature is advantageous because energy consumption, material stress and thermal exposure of operating personnel are reduced. In this way, the risk of burns to operating personnel due to inadvertent contact with the exposed reactor shell is reduced in the event that one or more cooling zones are disassembled.

[0042] A sixteenth 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] A seventeenth aspect of the invention relates to the use of an oxidation reactor according to claims 1 to 15 for the non-catalytic partial oxidation (POX) of a hydrocarbon-containing feed stream to a product stream containing hydrogen and carbon oxides.

[0044] An eighteenth aspect of the invention relates to the use of an oxidation reactor according to claim 16 for the autothermal reforming (ATR) of a hydrocarbon-containing feed stream into a product stream containing hydrogen and carbon oxides.

[0045] A nineteenth aspect of the present invention relates to the use of an oxidation reactor according to claims 1 to 15 for the partial oxidation of an ammonia-containing feed stream to form a product stream comprising hydrogen and nitrogen.

[0046] A twentieth aspect of the present invention is directed to a process for producing a product stream comprising hydrogen and carbon oxides from a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream.

[0047] A twenty-first aspect of the present invention is directed to a process for producing a product stream comprising hydrogen and carbon oxides from a hydrocarbon-containing feed stream and an oxygen-containing oxidant stream.

[0048] A twenty-second 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.

[0049] Working Example

[0050] 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

[0051] Figure 1 is a schematic diagram of a first configuration of an oxidation reactor according to the present invention;

[0052] Figure 2 is a schematic diagram of a second configuration of an oxidation reactor according to the present invention;

[0053] Figure 3 is a schematic diagram of a third configuration of an oxidation reactor according to the present invention;

[0054] Figure 4 is a schematic diagram of a fourth configuration of an oxidation reactor according to the present invention.

[0055] Hereinafter, "not shown" means that the element in the figure in question is not graphically represented, but is still present. DETAILED DESCRIPTION

[0056] Figure 1 A schematic diagram of a first configuration of an oxidation reactor 1 according to the present invention is shown, which is used for partially oxidizing a feed stream with an oxygen-containing oxidant stream to obtain a hydrogen-containing product stream. The oxidation reactor comprises a pressure-rated reactor shell 10 composed of a metallic material, which is a cylindrical structure over part of its length and has a first wall thickness. A first protective layer 20 composed of a first refractory material with a second wall thickness is installed in the reactor shell. A second protective layer 30 composed of a second refractory material with a third wall thickness is installed in the first protective layer. In the second protective layer, there is an empty volume 40 as a reaction chamber.

[0057] 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 50, the feed stream is introduced into the oxidation reactor 1 through the burner via the pipeline 2, and the oxygen-containing oxidant stream is introduced into the oxidation reactor 1 through the burner via the pipeline 3. Optionally, a moderator stream containing steam and / or carbon dioxide may be introduced into the oxidation reactor via the pipeline 2 or the pipeline 3 or a separate pipeline not shown, or a combination of at least two of these pipelines.

[0058] At the outlet end of the reactor housing, a pipe 4 is installed as an outlet, and the product flow can be discharged through this pipe 4. The connection between the pipe 4 and the reaction chamber is only shown in a schematic form, and the technical details are not shown. However, it is clear to those skilled in the art how to configure this connection.

[0059] Mounted on the reactor shell 10 is a first cooling zone 60, which is constructed so that it surrounds the reactor shell 10 and so that with the help of the first cooling zone 60, a first section of the reactor shell 10 can be cooled with the aid of a first fluid cooling medium, which is introduced into the first cooling zone 60 via a pipe 61 in a cold state and, after absorbing a portion of the heat released in the oxidation reactor, is discharged from the first cooling zone 60 in a heated state via a pipe 62.

[0060] Also mounted on the reactor shell 10 is a second cooling zone 70, which is constructed so that it surrounds the reactor shell 10 and so that, with the aid of the second cooling zone 70, a second section of the reactor shell 10 can be cooled with the aid of a second fluid cooling medium, which is introduced into the second cooling zone 70 via a pipe 71 in a cold state and, after absorbing a further portion of the heat released in the oxidation reactor, is discharged from the second cooling zone 70 in a heated state via a pipe 72.

[0061] The cooling medium heated in the first and / or second cooling zone 60, 70 is then cooled by one or more coolers (not shown) and directed back to the first and / or second cooling zone 60, 70 in a cooled form, which forms one or more cooling medium loops. The heat extracted from the cooling medium heated during the cooling process can be recovered by indirect heat exchange and used, for example, as process heat in an adjacent system / plant.

[0062] Figure 2 A schematic diagram of a second configuration of an oxidation reactor according to the present invention is shown. Unless otherwise specified in the context, the same reference numerals represent 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.

[0063] and Figure 1Compared to the embodiment of the present invention shown in the drawings, the first cooling zone 60 and the second cooling zone 70 are interconnected via pipes 61 and 72, so that the cooling medium first enters the second cooling zone 70 via pipe 71, where it absorbs a portion of the heat released in the oxidation reactor. The cooling medium then enters the first cooling zone 60 via pipe 72, where it absorbs another portion of the heat released in the oxidation reactor. Finally, the cooling medium is discharged from the first cooling zone via pipe 62. Therefore, the overall result is that the flow direction of the cooling medium is countercurrent relative to the flow direction of the reactant and product gas streams of the oxidation reactor. With the help of a pump and a cooler (both not shown), a cooling medium loop is formed. In addition, in one embodiment, an additional cold cooling medium flow can be introduced into the first cooling zone 60 via a pipe (not shown). In addition, in one embodiment, an additional warm cooling medium flow can be discharged from the second cooling zone 60 via a pipe (not shown). The configuration according to the latter two embodiments additionally increases the choice of use and improves the control of the temperature of the oxidation reactor.

[0064] Figure 3 A schematic diagram showing a third configuration of an oxidation reactor according to the present invention is shown. With regard to the configuration of the cooling zone, this configuration corresponds to Figure 1 The configuration shown differs in that the oxidation reactor is an autothermal reformer comprising an ATR catalyst bed 80 in the lower part of the reaction chamber 40. For operation of the oxidation reactor as an autothermal reformer and with an oxygen-containing oxidant, steam is introduced into the oxidation reactor via conduit 2 or conduit 3 or a separate conduit not shown, or a combination of at least two of these conduits.

[0065] Figure 4 A schematic diagram showing a fourth configuration of an oxidation reactor according to the present invention is shown. With regard to the configuration of the cooling zone, this configuration corresponds to Figure 1 The structure shown is different in that the second protective layer 30 is provided with periodic circumferential expansion gaps 35 and / or longitudinal expansion gaps (not shown). This oxidation reactor with expansion gaps is also suitable for Figure 1 , 2 The expansion gap may also be extended to the upper frustoconical portion and the outlet side portion of the second protective layer (both not shown).

[0066] In other embodiments, Figure 1 , 2 In the oxidation reactor 1 shown in FIGS. 3 and 4, the first cooling zone and the second cooling zone 60, 70 can be operated separately and can be assembled and disassembled separately (not shown). As a result, in one embodiment, if, for example, only a certain point of the reactor shell needs to be inspected or repaired, the operation of the oxidation reactor can continue. The operation of the oxidation reactor 1 can be continued for the duration of the inspection or maintenance measures, thereby avoiding production downtime.

[0067] In other embodiments, Figure 1 , 2 , 3 and 4, the flow of cooling medium through the first and second cooling zones 60, 70 is individually controllable (not shown). In this way, a better / more refined response to local differences in the thermal budget of the oxidation reactor is possible, so that the result is improved temperature control of the oxidation reactor.

[0068] In other embodiments, Figure 1 , 2 In the oxidation reactor 1 shown in , 3 and 4, the pressure of the cooling medium in the first cooling zone and the second cooling zone 60, 70 is individually controllable (not shown). In this way, a better / more refined reaction to local differences in the thermal budget of the oxidation reactor is also possible, so that the temperature control of the oxidation reactor is improved as a result. For example, one cooling zone 60 or 70 can be operated with a boiling cooling medium, which leads to a particularly intensive heat transfer, while the cooling medium in the other cooling zone remains as a single-phase fluid.

[0069] In other embodiments, Figure 1 , 2 In the oxidation reactor 1 shown in FIGS. 3 and 4, a common first and second fluid cooling medium is used, which flows through the first cooling zone and the second cooling zone 60, 70 (not shown). The use of a common cooling medium simplifies the construction of the coolant circuit. In one embodiment, the first cooling zone and the second cooling zone 60, 70 are embedded in the common cooling medium circuit, and the cooling medium flows through them in parallel or sequentially.

[0070] In other embodiments, Figure 1 , 2 , 3 and 4, the first cooling zone and the second cooling zone 60, 70 are fluidly connected, and the mass flow of the cooling medium through the first cooling zone and the second cooling zone 60, 70 is independently controllable (not shown). This configuration combines the advantages of a simplified coolant circuit and improved temperature control of the oxidation reactor.

[0071] In other embodiments, Figure 1 , 2 In the oxidation reactor 1 shown in FIGS. 3 and 4, a cooling device for intermediate cooling of the cooling medium is present between the first cooling zone and the second cooling zone (not shown). This configuration is advantageous when the cooling medium in the two cooling zones is kept as a single-phase fluid, but a large amount of heat still needs to be removed from the first cooling zone.

[0072] In other embodiments, Figure 1, 2 In the oxidation reactor 1 shown in , 3 and 4, there are more than two cooling zones (not shown). Although this configuration increases the complexity of the structure, in this way, even better / more refined reactions are possible for local differences in the thermal budget of the oxidation reactor, resulting in a further improved temperature control of the oxidation reactor.

[0073] In other embodiments, Figure 1 , 2 In the oxidation reactor 1 shown in , 3 and 4, a common cooling medium is used, which flows through all cooling zones 60, 70, etc. (not shown), 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 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.

[0074] In other embodiments, Figure 1 , 2 In the oxidation reactor 1 shown in FIGS. 3 and 4 , the inlet end is a truncated conical structure, which is connected to the burner 50 in an airtight / gas-tight manner at its narrow end and is connected to the reactor shell 10 in an airtight manner at its wide end.

[0075] In other embodiments, Figure 1 , 2 , 3 and 4, the thermal conductivity of the first protective layer is lower than the thermal conductivity of the second protective layer. The advantage of this configuration is the reduced effect of the lower thermal conductivity of the first protective layer on the heating of the reactor shell, especially when one or more cooling zones are not in operation.

[0076] In other embodiments, Figure 1 , 2 In the oxidation reactor 1 shown in FIGS. 3 and 4, a large number of expansion gaps (not shown) exist in the first and / or second protective layer, and these expansion gaps are preferably evenly distributed along the circumference and / or length of the first and / or second protective layer 20, 30. In this way, damage to the protective layer due to thermal expansion is avoided.

[0077] In other embodiments, Figure 1 In the oxidation reactor 1 shown, an expansion gap in the form of an annular gap is provided between the reactor housing and the first protective layer and / or between the first protective layer and the second protective layer. In this way, damage to the protective layer due to thermal expansion is avoided.

[0078] In other embodiments, Figure 1 , 2In the oxidation reactor 1 shown in FIGS. 3 and 4, the wall thickness and / or thermal conductivity of the first and second protective layers 20, 30 are selected so that if no cooling medium passes through one or more cooling zones, the temperature of the reactor shell at its outer surface is in the range of 180° C. to 300° C., preferably in the range of 200° C. to 250° C. These specified temperatures are advantageous because energy consumption, material stress and thermal exposure of operating personnel are reduced.

[0079] In other embodiments, Figure 1 , 2 , 3 and 4, water is used as a common cooling medium, and the wall thickness and thermal conductivity of the first and second protective layers 20, 30 and the mass flow rate of the common cooling medium through the cooling zone are selected so that the temperature of the cooling medium discharged from the cooling zone is less than 100°C. This limited temperature is advantageous because it reduces energy consumption, material stress and thermal exposure of operators. In this way, the risk of burns to operators due to inadvertent contact with the exposed reactor shell is reduced in the event that one or more cooling zones are disassembled.

[0080] In other embodiments, Figure 1 , 2 The oxidation reactor 1 shown at 4 is used for the non-catalytic partial oxidation (POX) of a hydrocarbon-containing feed stream to obtain a product stream containing hydrogen and carbon oxides.

[0081] In other embodiments, Figure 1 , 2 The oxidation reactor 1 shown at 4 is used for partially oxidizing an ammonia-containing feed stream into a product stream containing hydrogen and nitrogen.

[0082] In another embodiment, Figure 3 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.

[0083] In another embodiment, Figure 3 The oxidation reactor shown is used for autothermal reforming (ATR) of an ammonia-containing feed stream into a product stream containing hydrogen and nitrogen.

[0084] 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:

[0085] (a) providing an oxidation reactor according to claims 1 to 15;

[0086] (b) introducing a hydrocarbon-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner;

[0087] (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);

[0088] (d) discharging a product stream comprising hydrogen and carbon oxides through an outlet.

[0089] 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:

[0090] (a) providing an oxidation reactor according to claim 16;

[0091] (b) introducing a hydrocarbon-containing feed stream, an oxygen-containing oxidant stream, and an optional moderator stream into a reaction chamber via a burner;

[0092] (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);

[0093] (d) discharging a product stream comprising hydrogen and carbon oxides through an outlet.

[0094] 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:

[0095] (a) providing an oxidation reactor according to claims 1 to 15;

[0096] (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;

[0097] (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;

[0098] (d) discharging a product stream comprising hydrogen and nitrogen through an outlet.

[0099] 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.

[0100] Reference numerals list

[0101] [1] Oxidation reactor

[0102] [2] Pipeline

[0103] [3] Pipeline

[0104] [4] Pipeline (export)

[0105]

[10] Reactor housing

[0106]

[20] First protective layer

[0107]

[30] Second protective layer

[0108]

[35] Expansion gap

[0109]

[40] Empty volume (reaction chamber)

[0110]

[50] Burner

[0111]

[60] First Cooling Zone

[0112]

[61] Cooling water pipes

[0113]

[62] Cooling water pipes

[0114]

[70] Second Cooling Zone

[0115]

[71] Cooling water pipes

[0116]

[72] Cooling water pipes

[0117]

[80] 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 shell constructed of a metallic material, the reactor shell being cylindrical over a portion of its length, having a longitudinal axis and having a first wall thickness; (b) a first protective layer mounted within the reactor housing, the first protective layer being composed of a first refractory material and having a second wall thickness; (c) a second protective layer installed within the first protective layer, the second protective layer being composed of a second refractory material and having a third wall thickness; (d) a void volume disposed within the second protective layer, the void volume serving as a reaction chamber; (e) an inlet for a feed stream mounted at an inlet end of the reactor housing, wherein the inlet is configured as a burner through which the feed stream, the oxygen-containing oxidant stream, and an optional moderator stream can be introduced into the reaction chamber; (f) an outlet mounted at the outlet end of the reactor housing through which the product stream can be discharged; (g) a first cooling zone mounted on the reactor shell around the reactor shell, by means of which a first section of the reactor shell can be cooled by means of a first fluid cooling medium; (h) a second cooling zone mounted on the reactor shell around the reactor shell, by means of which a second section of the reactor shell can be cooled by means of a second fluid cooling medium.

2. The oxidation reactor according to claim 1, characterized in that The first cooling zone and the second cooling zone are each independently operable and can be each independently assembled and disassembled.

3. The oxidation reactor according to claim 1 or 2, characterized in that: The flow of cooling medium through the first cooling zone and the flow through the second cooling zone are each independently controllable.

4. An oxidation reactor according to any one of the preceding claims, characterized in that The pressures of the cooling media in the first cooling zone and the second cooling zone are each independently controllable.

5. An oxidation reactor according to any one of the preceding claims, characterized in that Common first and second fluid cooling mediums are used that flow through the first cooling zone and the second cooling zone.

6. An oxidation reactor according to any one of the preceding claims, characterized in that The first cooling zone and the second cooling zone are fluidly connected, wherein the mass flow of the cooling medium through the first cooling zone and the second cooling zone is each independently controllable.

7. An oxidation reactor according to any one of the preceding claims, characterized in that A cooling device for intermediate cooling of the cooling medium is located between the first cooling zone and the second cooling zone.

8. An oxidation reactor according to any one of the preceding claims, characterized in that There are more than two cooling zones.

9. An oxidation reactor according to any one of the preceding claims, characterized in that A common cooling medium is used which flows through all cooling zones, with water being preferably used as the common cooling medium.

10. An oxidation reactor according to any one of the preceding claims, characterized in that The inlet end is a frustoconical structure, which is gas-tightly connected to the burner at its narrow end and gas-tightly connected to the reactor housing at its wide end.

11. An oxidation reactor according to any one of the preceding claims, characterized in that The thermal conductivity of the first protective layer is lower than the thermal conductivity of the second protective layer.

12. An oxidation reactor according to any one of the preceding claims, characterized in that There are multiple periodic circumferential expansion gaps and / or multiple expansion gaps along the longitudinal direction in the first protective layer and / or the second protective layer, and preferably, the multiple periodic circumferential expansion gaps and / or the multiple expansion gaps along the longitudinal direction are evenly distributed on the circumference and / or length of the first protective layer and / or the second protective layer.

13. An oxidation reactor according to any one of the preceding claims, characterized in that An expansion gap in the form of an annular gap is provided between the reactor housing and the first protective layer and / or between the first protective layer and the second protective layer.

14. An oxidation reactor according to any one of the preceding claims, characterized in that The wall thickness and / or the thermal conductivity of the first protective layer and the second protective layer are selected so that, without a cooling medium passing through one or more cooling zones, the temperature of the reactor shell at its outer surface is in the range of 180° C. to 300° C., preferably in the range of 200° C. to 250° C.

15. An oxidation reactor according to any one of the preceding claims, characterized in that Water is used as the common cooling medium, wherein the wall thickness and thermal conductivity of the first protective layer and the second protective layer and the mass flow rate of the common cooling medium through the cooling zone are selected so that the temperature of the cooling medium discharged from the cooling zone is below 100°C.

16. 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.

17. Use of an oxidation reactor according to claims 1 to 15 for the non-catalytic partial oxidation of a hydrocarbon-containing feed stream to a product stream containing hydrogen and carbon oxides.

18. Use of an oxidation reactor according to claim 16 for autothermal reforming of a hydrocarbon-containing feed stream into a product stream containing hydrogen and carbon oxides.

19. Use of an oxidation reactor according to claims 1 to 15 for the partial oxidation of an ammonia-containing feed stream to form a product stream containing hydrogen and nitrogen.

20. 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 15; (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 the hydrocarbon-containing feed stream and the oxygen-containing oxidant stream in the burner and / or in the reaction chamber under conditions for non-catalytic partial oxidation; (d) discharging the product stream comprising hydrogen and carbon oxides through an outlet.

21. 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 16; (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 the hydrocarbon-containing feed stream and the 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.

22. 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 15; (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; (c) converting the ammonia-containing feed stream and the oxygen-containing oxidant stream in the burner and / or in the reaction chamber under conditions for non-catalytic partial oxidation of ammonia; (d) discharging the product stream comprising hydrogen and nitrogen via an outlet.

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