Fluid reactor

Abstract

There is a need to provide a system capable of meeting the thermal requirements of high-temperature reactions, in particular high-temperature reactions relating to molten substances. A novel fluid reactor and methods of using the reactor are provided. A reactor for reacting a fluid with a gas comprises two first containers in direct contact with two second containers, in which apertures are arranged in series to direct the fluid in the first containers to flow and flow through the apertures of each first container and into the connected second containers by gas entering each first container via a gas inlet, and the apertures of the second containers allow fluid flowing from each first container through each second container to flow into the first containers connected to the second containers.

Description

Priority Document

[0001] This application claims priority to Australian Provisional Patent Application No. 2022903068, entitled “Multi-Vessel Fluid Reactor” and filed on October 18, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0002] The present disclosure relates to a novel fluid reactor and methods of using the same. In a particular form, the present disclosure relates to a fluid reactor suitable for reacting a fluid with a gas that facilitates the distribution of heat through the fluid. Background Art

[0003] Molten materials, such as pure metals, salts, and alloys, are used as catalysts in many industrial processes. One problem with using molten materials as catalysts for endothermic reactions is how to provide the heat to drive the reaction without heating the medium through the reactor walls. One challenge with heating the medium through the walls occurs when using reactive molten media, such as molten metals, because any coating of the walls with a protective lining to protect the reactor walls will also inhibit heat transfer, as these coatings are typically thermally insulating materials. Another challenge with heating the medium through the walls occurs when the reaction produces fine particles, such as occurs with methane pyrolysis reactions, because heating through the walls will preferentially cause the particles to deposit on the reactor walls, which will inhibit the reaction process and create maintenance challenges. It is also necessary to minimize heat losses through the walls in circulating fluid reactors by reducing the surface area with the external environment. This is necessary to ensure that the fluids remain molten at all locations within the reactor to be effective, especially when they are used to catalyze endothermic reactions involving gases. Therefore, the system used to carry out reactions involving these catalysts needs to be able to provide sufficiently high temperatures to keep the catalyst molten at all locations within the reactor. This is especially true for liquid metals. If the temperature at any location becomes too low, the liquid metal solidifies, resulting not only in inefficient reactions and low product yields, but also in clogging the system.

[0004] WO2018 / 132875 describes a device that can be used as a reactor system for fluids and gases, which uses concentrated solar radiation as a heat source. WO2019 / 226416 describes an alternative reactor system for fluids and gases. However, none of these documents provides a reactor system that adequately handles heat losses.

[0005] It is therefore desirable to provide a system that can meet the thermal requirements of high temperature reactions, particularly those involving molten materials. Alternatively, or in addition, a method is needed to separate the particles produced in the reaction within a molten metal reactor for situations where the particle density is less than that of the molten medium. This is the case in methane pyrolysis, where the carbon product will normally float to the top of the reactor. In order to allow the reactor to operate continuously, it is necessary to provide a method for continuously removing the floating carbon from the top of the reactor. Summary of the invention

[0006] According to a first aspect, there is provided a reactor for reacting a fluid with a gas, the reactor comprising:

[0007] two first containers, each first container comprising a gas inlet; and

[0008] Two second containers,

[0009] wherein one of the second containers is located between two first containers such that the second container is in direct contact with each first container, and at least one first container is located between two second containers such that the first container is in direct contact with each second container, wherein the direct contact promotes heat exchange between the containers, and

[0010] wherein each first container and each second container comprises a hole, wherein:

[0011] the aperture of each first container connects each first container to at least one second container,

[0012] the hole of each second container is located at the bottom of each second container,

[0013] the hole of the first container is located above the hole of the second container, and

[0014] The holes are arranged in series,

[0015] The fluid in the first containers is guided to flow toward and through the holes of each first container and into the connected second container by the gas entering each first container through the gas inlet, and the holes of the second containers allow the fluid flowing from each first container and through each second container to flow into the first container connected to the second container.

[0016] At least one of the holes of the first container may be located at the top of the reactor. At least one of the holes of the first container may be a gap between a side wall of one of the first containers and the top of the reactor. At least one of the holes of the first container may be a hole in a side wall of one of the first containers. At least one of the holes of the second container may be located at the bottom of the reactor. At least one of the holes of the second container may be a gap between a side wall of one of the second containers and the bottom of the reactor. At least one of the holes of the second container may be a hole in a side wall of one of the second containers.

[0017] In at least one of the first containers, the gas inlet may be located at the bottom of the container.

[0018] In one form, each first vessel is located between, in direct contact with, and connected to two second vessels such that fluid flowing through the reactor moves through the vessels in a circular motion when viewed from above or below.

[0019] The reactor may also include at least one gas outlet. The gas outlet may be located in the reactor or at the top of the reactor.

[0020] At least one first container may also include at least one product outlet. The product outlet may be located at the top of the first container. The weir may be configured to retain the fluid in the reactor and allow the product to enter the product outlet of the first container. At least one second container may also include a product outlet. The product outlet may be located at the top of the second container. The weir may be configured to retain the fluid in the reactor and allow the product to enter the product outlet of the second container.

[0021] At least one first container may further include a feed inlet. The feed inlet may be located at the bottom of the container.

[0022] Also provided is a method of reacting a fluid with a gas to produce a solid product, the method comprising:

[0023] · providing a reactor as described herein, wherein the reactor comprises a fluid in a first container (container A);

[0024] Introducing a reactive gas for mixing and reacting with the fluid into container A, causing the gas to pass through the fluid, and directing the fluid-gas mixture to flow toward and through the aperture of container A and into a connected second container (container B), wherein the aperture of container B allows the fluid flowing from container A through container B to flow to another first container (container C);

[0025] Introducing a second gas into container C, the second gas directing the fluid-gas mixture to flow toward and through the apertures of container C and into a connected second container (container D), wherein the apertures of container D allow the fluid flowing from container C through container D to flow back into container A;

[0026] Collect the solid product from the product outlet.

[0027] The fluid may be selected from molten metal, molten salt, molten alloy or a combination thereof. The fluid may be a molten catalyst.

[0028] The reaction gas may be natural gas. The reaction gas may include methane. The reaction gas may consist of methane. The solid product may be carbon.

[0029] The second gas may be an inert gas. The inert gas may be heated. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Some embodiments of the present disclosure will be discussed with reference to the accompanying drawings, in which:

[0031] Figure 1 is a schematic diagram of a top view of one embodiment of a reactor of the present invention, which includes four vessels directly contacting to form a cylindrical reactor.

[0032] Figure 2 is a schematic diagram of a side view of one embodiment of a reactor of the present invention, which includes four vessels in direct contact and connected using weirs.

[0033] Figure 3 It is rotated about 90 degrees. Figure 2 Schematic diagram of a side view of an embodiment of a reactor of the present invention.

[0034] Figure 4 Schematic diagram of an isometric view of an embodiment of the reactor of the present invention, which includes four containers directly in contact and connected using weir holes. The molten fluid circulating in the reactor is represented by solid arrows in the foreground and dashed arrows in the background.

[0035] Figure 5 It is rotated about 90 degrees. Figure 4 Schematic diagram of an isometric view of one embodiment of a reactor of the present invention. For the sake of clarity, the molten fluid circulating in the reactor is omitted.

[0036] Figure 6 Schematic diagram of an isometric view of one embodiment of the reactor of the present invention, which includes four containers in direct contact and connected using gate holes. For the sake of clarity, the molten fluid circulating in the reactor is omitted.

[0037] Figure 7 is a schematic diagram of a top view of an embodiment of a reactor of the present invention, which includes four containers directly contacting to form an approximately quadrangular prism reactor.

[0038] Figure 8is a schematic diagram of a side view of one embodiment of a reactor of the present invention comprising four vessels in direct contact and connected using weirs. An alternative embodiment of the outlet is shown.

[0039] Fig. 9 It is rotated about 90 degrees. Figure 2 Schematic diagram of a side view of one embodiment of a reactor of the present invention. An alternative embodiment of the outlet is shown with a product overflow weir.

[0040] Fig.10 It is rotated about 90 degrees. Figure 2 Schematic diagram of a side view of one embodiment of a reactor of the present invention.

[0041] Fig.11 It is rotated about 90 degrees. Figure 2 Schematic diagram of a side view of one embodiment of a reactor of the present invention. An alternative embodiment of the outlet is shown with a product overflow weir.

[0042] Fig.12 Schematic diagram of an isometric view of an embodiment of a reactor of the present invention, which includes four containers in direct contact and connected using gate holes. For the sake of clarity, the molten fluid circulating in the reactor is omitted. An embodiment of an outlet is shown, wherein the outlet is in the second container.

[0043] Fig.13 Schematic diagram of an isometric view of an embodiment of a reactor of the present invention, which includes four containers in direct contact and connected using gate holes. For the sake of clarity, the molten fluid circulating in the reactor is omitted. An embodiment of an outlet is shown, wherein the outlet is in the first container.

[0044] Fig.14 is a schematic diagram of a cross-sectional view of an embodiment of a reactor of the present invention, which includes four vessels in direct contact and connected using weir holes. An embodiment of the movement of the molten fluid and the product circulating in the reactor is shown.

[0045] In the following description, the same reference numerals denote the same or corresponding parts throughout the drawings. DETAILED DESCRIPTION

[0046] The inventors have developed a new type of reactor in which the constituent vessels are in direct contact with each other, allowing for more efficient management of heat in the reactor. This arrangement mitigates heat loss from the fluid, allowing the molten material to remain in a fluid state for a longer period of time, resulting in a more efficient reaction. By more effectively maintaining the material in a molten state, the likelihood of clogging is reduced.

[0047] Reference now Figure 1-Figure 14 , which shows a reactor 10 comprising four containers. Figure 1-Figure 14 In the illustrated embodiment, four containers 20, 30, 40, 50 are formed by dividing the cylindrical reactor 10 into four parts using vertical partitions. However, those skilled in the art will appreciate that the reactor 10 can be formed using four (or more) containers in some different ways. For example, four (or more) otherwise separate containers can be placed together so that they are in direct contact with each other. All such alternatives are intended to fall within the scope of the present invention.

[0048] "Direct contact" means that each of the containers 20, 30, 40, 50 is in physical contact with at least one other container, so that heat can be easily exchanged between the containers 20, 30, 40, 50 that are in direct contact with each other through the point of direct contact. Typically, this direct contact will be achieved by the side walls 23, 33, 43, 53 of the containers 20, 30, 40, 50 contacting each other, or, in the case of Figure 1-Figure 14 In the case of the embodiment shown, this can be achieved by the containers 20, 30, 40, 50 sharing one or more side walls 23, 33, 43, 53. Therefore, in the reactor 10 of the present disclosure including two first containers 20, 30 and two second containers 40, 50, one of the second containers 40, 50 is located between the two first containers 20, 30, so that the second container 40, 50 is in direct contact with each of the first containers 20, 30, and at least one first container 20, 30 is located between the two second containers 40, 50, so that the first container 20, 30 is in direct contact with each of the second containers 40, 50, wherein the direct contact promotes heat exchange between the containers 20, 30, 40, 50. In one form of the reactor 10 of the present invention, each of the first vessels 20, 30 is located between, in direct contact with, and connected to two second vessels 40, 50, such that a fluid 60 flowing through the reactor 10 moves in a circular motion through the vessels 20, 30, 40, 50. An example of this arrangement is illustrated in the figure, wherein all of the vessels 20, 30, 40, 50 are in direct contact with each other.

[0049] Gas 61, 62 is introduced (e.g., injected) into the bottom of each first container 20, 30 through a gas inlet 24, 34 (e.g., a nozzle (e.g., a sprinkler)) to start the circulation of fluid 60 through the reactor 10. The reactor 10 of the present invention is particularly suitable for molten materials. The fluid 60 can be selected from molten metal, molten salt, molten alloy or a combination thereof. The fluid 60 can be a molten catalyst. Examples of suitable molten catalysts include molten tin, molten gallium and Ni 0.27 Bi 0.73and other catalysts described in WO2019 / 226416 and WO2018 / 132875 (including molten metals, molten salts, molten alloys and combinations thereof). The gas may be a reaction gas 61. The reaction gas 61 may be any gas that is desired to contact or react with the fluid 60 to produce a product 63 of interest. The reaction gas 61 may be natural gas. The reaction gas 61 may be gas from a landfill. The reaction gas 61 may include methane. When the gas introduced into one first container 20 is the reaction gas 61, the gas introduced into another first container 30 may be an inert gas 62. The inert gas 62 may be heated and used to provide additional heat to the fluid flowing through the containers 20, 30, 40, 50. The gas introduced into the other first container 30 may be a reactive gas 61 that reacts with the fluid 60 (the same reactive gas 61 as introduced into the first container 20, or a different reactive gas 61), may be a gas introduced to induce lift to help the fluid 60 circulate through the containers 20, 30, 40, 50, or may be a combination of some or all of these gases. The movement of the gas 61 may be as follows: Figure 4 and Fig.14 Best shown.

[0050] Vessels 20, 30, 40, 50 and reactor 10 may be made of any material known to those skilled in the art to be suitable for use in high temperature reactors, such as stainless steel, which may also include a ceramic lining to provide additional protection.

[0051] A gas 61, 62 is introduced into each first container 20, 30 at a sufficient pressure to mix bubbles of the gas 61, 62 with the fluid 60 and direct the fluid 60 toward and through the apertures 28, 38 of each first container 20, 30 and into the connected second container 40, 50. The mixing of the gas 61, 62 bubbles with the fluid 60 reduces the density of the resulting fluid and gas 61, 62 mixture relative to the fluid 60 in the adjacent second container 40, 50. This density difference, together with the momentum of the gas 61, 62 jet, causes a "lift" within each first container 20, 30, causing the mixture to rise to the top 21, 31 of each first container 20, 30. Most of the gas 61, 62 bubbles separate from the fluid 60 at the top 21, 31 of each first container 20, 30, while the remaining entrained bubbles pass through the apertures 28, 38 with the fluid 60 and separate from the fluid 60 in each second container 40, 50. The fluid 60 passing through the holes 28, 38 of each first container 20, 30 moves downward to the bottom of the next second container 40, 50 due to circulation and gravity. Then, the fluid 60 passes through the holes at the bottom of each second container 40, 50 to reach the bottom of the next first container 20, 30 to continue the process. In this way, as the fluid 60 passes through the containers 20, 30, 40, 50, the fluid 60 causes a cyclic wave-like motion. The cyclic wave-like motion is as follows: Figure 4 shown.

[0052] Those skilled in the art will appreciate that the gas inlet 24, 34 should be located in each first container 20, 30 so that the fluid 60 is directed to flow toward and through the holes 28, 38 of each first container 20, 30, and into the connected second container 40, 50. Thus, the gas inlet 24, 34 may be present in each first container 20, 30 at the bottom of these containers. By "at the bottom of the container" is meant that the gas inlet 24, 34 is located at or near the base of the container 20, 40 to achieve the desired lifting movement of the fluid 60 and adequate mixing with the heated reaction gas 61 introduced into each first container 20, 30 via the gas inlet 24, 34.

[0053] In the reactor 10 of the present invention, each first container 20, 30 and each second container 40, 50 include holes 28, 38, 48, 58. The holes 28, 38 of each first container 20, 30 connect each first container 20, 30 with at least one second container 40, 50, the holes 48, 58 of each second container 40, 50 are located at the bottom of each second container 40, 50, the holes 28, 38 of the first container 20, 30 are located above the holes 48, 58 of the second container 40, 50, and the holes 28, 38, 48, 58 are arranged in series. In this way, as described above, when the fluid 60 passes through the container 20, 30, 40, 50, a cyclic wave-like motion is induced in the fluid 60. It will be understood by those skilled in the art that the containers 20, 30, 40, 50 described herein inherently have a top and a bottom. Thus, the container 20, 30, 40, 50 described herein includes a top 21, 31, 41, 51 (which may be open and thus may be referred to as a "top portion") and a bottom 22, 32, 42, 52. The container 20, 30, 40, 50 is configured to contain a fluid 60, such as a molten substance as discussed herein.

[0054] At least one of the holes 28, 38 of the first container 20, 30 can be located at the top 11 of the reactor 10. Those skilled in the art will understand that the reactor 10 described herein inherently has a top and a bottom. Therefore, the reactor 10 described herein includes a top 11 and a bottom 12. "At the top of the reactor" means that the holes 28, 38 are at least partially formed by the top 11 of the reactor 10, or are located near the top 11 of the reactor 10 (for example, near the top of the sidewall 23, 33 of the first container 20, 30) to achieve the desired movement of the fluid 60 through the holes 28, 38, that is, to allow the fluid 60 flowing upward under the action of the gas 61, 62 to pass through, and then after the fluid has passed through the holes 28, 38, the fluid 60 moves downward in the adjacent second container 40, 50. However, those skilled in the art will understand that as long as the movement of the fluid 60 is achieved, the holes 28, 38 of each first container 20, 30 can be located at any suitable height above the holes 48, 58 of each second container 40, 50.

[0055] Regarding the shape and configuration of the holes 28, 38, 48, 58, they can be any suitable shape and configuration that allows the fluid 60 (or a mixture of the fluid 60 and the gases 61, 62) to pass through. Figure 1-Figure 5 and Figure 7-Figure 14 As best shown, one or more of the apertures 28, 38 of the first container 20, 30 may be a gap between the side wall 23, 33 of one of the first containers 20, 30 and the top 11 of the reactor 10, or as Figure 6As best shown, it is a hole in the side wall 23, 33 of one of the first containers 20, 30. In embodiments where the one or more holes 28, 38, 48, 58 are gaps between the side wall 23, 33 of one of the first containers 20, 30 and the top 11 of the reactor 10, the top edge of the side wall 23, 33 can form an overflow weir. The overflow weir can take any suitable shape. Some shapes (such as Figure 5 The rectangular cutout shown, or Fig.12 and Fig.13 straight edge as shown). Figure 1-Figure 5 and Figure 7-Figure 14 As best shown, at least one of the apertures 48, 58 of the second vessel 40, 50 may be a gap between a side wall 43, 53 of one of the second vessels 40, 50 and the bottom 12 of the reactor 10 (e.g., a downflow weir), or as Figure 6 As best shown, this is a hole in the side wall 43, 53 of one of the second containers 40, 50. At least one of the holes 48, 58 of the second container 40, 50 can be located at the bottom 12 of the reactor 10. By "at the bottom of the reactor" is meant that the hole 48, 58 is at least partially formed by the bottom 12 of the reactor 10, or is located near the bottom 12 of the reactor 10 (e.g., near the bottom of the side wall 43, 53 of the second container 40, 50) to achieve the desired movement of the fluid 60 through the hole 48, 58, i.e., to allow the fluid 60 to pass downwardly through the second container 40, 50 under the action of gravity, thereby entering the bottom of the next first container 20, 30 through the hole 48, 58.

[0056] The reactor 10 may also include at least one gas outlet 44, 54. In some embodiments, there is one gas outlet 44. The illustrated embodiment shows two gas outlets 44, 54, but the reactor 10 is not limited to two gas outlets. In some embodiments, there are two or more gas outlets. The gas outlets 44, 54 may be located in or at the top 11 of the reactor 10. The gas outlets 44, 54 are typically used to allow excess gas 67 (e.g., unreacted or overheated reaction gas 61, used or overheated inert gas 62, and / or gas produced by reactions occurring in the reactor 10) to leave the reactor 10, thereby maintaining the pressure within the reactor 10 at a desired level. "In the top of the reactor" means that the gas 67 flows out of the top 11 of the reactor 10. Figure 1-Figure 14 An example of this arrangement is given. One skilled in the art can readily determine the appropriate size and shape of the outlets 44, 54 to allow excess gas 67 to exit the reactor 10. In some embodiments, the gas outlets 44, 54 may be nozzles.

[0057] The gas outlets 44, 54 may be in communication with the head space 14 of the reactor 10. The head space 14 is generally located above the fluid 60 within the reactor 10 and may be one space or divided into multiple spaces, depending on the type of reactants to be used, the purity to be achieved for the product 63, and the type of product 63 to be produced. In embodiments where the head space 14 is divided into multiple spaces, each space may be in communication with its own gas outlet 44, 54.

[0058] As shown, at least one of the first containers 20, 30 may also include at least one product outlet 66. Fig.13 As shown, the product outlet 66 can be located at the top 21, 31 of the first container 20, 30. In the event that the product 63 of the reaction between the fluid 60 and the gas 61, 62 is a solid, the solid can float to the top of the fluid 60 in the first container 20, 30 and be separated and removed from the container 20, 30 through the product outlet 66. Any remaining solids can flow into the second container 40, 50 through the holes 28, 38 along with the fluid 60 and can be removed through the product outlet 66 located at the top 41, 51 of the second container 40, 50. Therefore, at least one of the second containers 40, 50 can also include a product outlet 66. This Fig.12 shown.

[0059] The figures illustrate two embodiments in which the product outlet 66 is located in one of the first containers 20, 30 or one of the second containers 40, 50 (e.g. Fig.12 and Fig.13 ). In some embodiments, the reactor 10 has a product outlet 66 in one of the first containers 20, 30 and one of the second containers 40, 50. In other embodiments, the reactor 10 has a product outlet 66 in each of the first containers 20, 30 and the second containers 40, 50. In another embodiment, the reactor 10 has a product outlet 66 in each of the second containers 40, 50 or each of the first containers 20, 30, or any suitable combination. A person skilled in the art can easily determine the appropriate container 20, 30, 40, 50 for the product outlet 66 based on the location where the product 63 accumulates.

[0060] The product outlet 66 may be implemented as follows: Fig.14 As best shown, the product outlet 66 is shown at the top 41, 51 of the second container 40, 50. Some other embodiments are Figure 1-13 "At the top of the container" means that the product outlet 66 is located at or near the top 21, 31, 41, 51 of the container 20, 30, 40, 50 (for example, near the top of the side wall 23, 33 of the first container 20, 30) to allow the product 63 floating to the top of the fluid 60 to flow out of the container 20, 30 and out of the reactor 10. Figure 4 , Fig.12 , Fig.13 and Fig.14 As best shown, the product outlet 66 may include a weir 64 configured to retain the fluid 60 in the reactor 10 and allow the product 63 to move over the weir 64. The product 63 may then enter the product outlet 66. The weir 64 may be of any suitable configuration. The height of the weir 64 may be equal to or higher than the height of the holes 28, 38 of the first container 20, 30. The relative heights of the weir 64 and the holes 28, 38 may be selected so that the level of the fluid 60 may be at or below the top edge of the weir 64 and at a level such that the fluid 60 may flow through or over the holes 28, 38. The product 63 that floats to the top of the fluid 60 may then move over the weir 64 to the product outlet 66 while the fluid 60 remains in the reactor 10. The product 63 may be pushed over the weir 64 by, for example, the effect of further accumulating the product 63. In the illustrated embodiment, the product 63 is pushed over the weir 64 and accumulates in the chamber 70 before being discharged through the outlet 66. A person skilled in the art can readily determine a suitable configuration of weir 64, chamber 70, and outlet 66, for example, chamber 70 may not be present, such that product 63 is pushed over weir 64 and discharged through outlet 66. Alternatively, sidewalls 23, 33, 43, 53 of container 20, 30, 40, 50 may perform the function of weir 64, such that product 63 is pushed through outlet 66, for example, as Figure 5 and Figure 6 In other embodiments, chamber 70 may be enlarged to temporarily store product 63 before product 63 is removed from chamber 70 .

[0061] Weir 64 may be located in any suitable position to retain fluid 60 within reactor 10. Fig.14 In the illustrated embodiment, the weir 64 is formed by the sidewall 43, 53 of the second container 40, 50. In other embodiments, the weir 64 is located on or near the outer sidewall 23, 33 of the first or second container 20, 30. The weir 64 can be aligned with the sidewall 23, 33, 43, 55 of either the first container 20, 30 or the second container 40, 50. Fig.12 In the embodiment, the weir 64 is in the form of an overflow weir 64 parallel to the side wall 23 of the first container including the hole 28. Fig.13 In the embodiment of the present invention, the weir 64 is parallel to the side wall 43 of the second container including the hole 48 in the form of a downstream weir 64. The angle of the weir 64 can be determined by a person skilled in the art to use the movement of the fluid 60 to push the product 63 over the weir 64.

[0062] like Figure 5 , Fig.12 and Fig.14As shown, at least one of the first containers 20, 30 may further include a feed inlet 27. The feed inlet 27 may be located at the bottom 22, 32 of the first container 20, 30. The feed inlet 27 may be used to introduce a fluid 60 into the first container 20, 30. At least one of the second containers 40, 50 may further include a feed inlet (not shown). The feed inlet may be located at the bottom 42, 52 of the second container 40, 50. "At the bottom of the container" means that the feed inlet 27 is located at the base of the container 20, 30, 40, 50 or near the base of the container 20, 30, 40, 50 to allow the fluid 60 to be introduced into the container 20, 30, 40, 50.

[0063] The present invention also relates to a method for reacting a fluid with a gas to produce a solid product, the method comprising:

[0064] Providing a reactor as described herein, wherein the reactor contains a fluid in a first vessel (vessel A);

[0065] Introducing a reactive gas for mixing and reacting with the fluid into container A, causing the gas to pass through the fluid, and directing the fluid-gas mixture to flow toward and through the aperture of container A and into a connected second container (container B), wherein the aperture of container B allows the fluid flowing from container A through container B to flow to another first container (container C);

[0066] Introducing a second gas into container C, the second gas directing the fluid-gas mixture to flow toward and through the apertures of container C and into a connected second container (container D), wherein the apertures of container D allow the fluid flowing from container C through container D to flow back into container A;

[0067] Collect the solid product from the product outlet.

[0068] The fluid may be selected from molten metal, molten salt, molten alloy or a combination thereof. The fluid may be a molten catalyst. Examples of suitable molten catalysts include molten tin, molten gallium and Ni 0.27 Bi 0.73 and other catalysts described in WO2019 / 226416 and WO2018 / 132875 (including molten metals, molten salts, molten alloys and combinations thereof).

[0069] The reaction gas may be any gas that is desired to contact or react with the fluid to produce a product of interest. The reaction gas may be natural gas. The reaction gas may include methane. The reaction gas may consist of methane. The reaction gas may be a combination of hydrocarbons with steam or CO2 for dry or wet gasification.

[0070] The solid product may be carbon. Thus, the reaction may be the pyrolysis of methane (CH4 → 2H2 + C) or any other gas or hydrocarbon.

[0071] When the gas introduced into one of the first vessels is a reactive gas, the second gas may be an inert gas. The inert gas may be heated and used to provide additional heat to the fluid flowing through the vessel. The second gas may be a reactive gas that reacts with the fluid (the same reactive gas as introduced into the first vessel, or a different reactive gas), may be a gas introduced to induce lift to help circulate the fluid through the vessel, or may be a combination of some or all of these gases.

[0072] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that such prior art forms part of the common general knowledge.

[0073] It should be understood that the terms “comprise” and “include” and any derivatives thereof (for example, comprises, comprising and includes, including) used in this specification and the appended claims should be construed as including the features to which the terms refer, and unless otherwise stated or implied, are not intended to exclude the existence of any other features.

[0074] In some cases, for the sake of brevity and / or to help understand the scope of the present disclosure, a single embodiment may combine multiple features. It should be understood that in this case, these multiple features may be provided separately (in separate embodiments) or in any other suitable combination. Alternatively, where separate features are described in separate embodiments, these separate features may be combined into a single embodiment unless otherwise stated or implied. This also applies to claims that can be recombined in any combination. That is, the claims can be amended to include features defined in any other claim. In addition, phrases referring to "at least one" in a list of items refer to any combination of these items, including single components. For example, "at least one of a, b, or c" is intended to cover: a, b, c, ab, ac, bc, and abc.

[0075] Example

[0076] One potential application of the reactor is to use a molten catalyst (such as molten tin, molten gallium or Ni 0.27 Bi 0.73) for methane pyrolysis. Therefore, the fluid circulating between the containers is a molten catalyst. Methane is introduced into one of the first containers through a gas inlet and is converted into hydrogen and carbon as it moves upward through the fluid and the container. This also causes an upward movement of the fluid in the container, which causes the molten catalyst to circulate through the container in the reactor. The heat required for the pyrolysis of methane, which is an endothermic reaction, can be provided by heating the molten catalyst by the reactor and / or the container wall, by injecting a high-temperature inert gas into another first container and / or by using resistive heating to heat the container wall. The inert gas also causes an upward lift and further accelerates the circulation of the fluid through the container. The product (solid carbon) floats to the surface of the first container (where the methane is injected), where it can be removed. The solid carbon can also be transferred to an adjacent second container with the fluid, where the solid carbon can also be removed.

[0077] Those skilled in the art will appreciate that the use of the present disclosure is not limited to the one or more specific applications described. The present disclosure in its preferred embodiments is also not limited to the specific elements and / or features described or depicted herein. It should be understood that the present disclosure is not limited to the one or more embodiments disclosed, but can be rearranged, modified and replaced in a variety of ways without departing from the scope set forth and defined by the appended claims.

Claims

1. A reactor for reacting a fluid with a gas, the reactor comprising: two first containers, each first container comprising a gas inlet; and Two second containers, wherein one of the second containers is located between the two first containers such that the second container is in direct contact with each first container, and at least one of the first containers is located between the two second containers such that the first container is in direct contact with each second container, wherein the direct contact promotes heat exchange between the containers, and wherein each of said first containers and each of said second containers comprises a hole, wherein: the aperture of each of the first containers connects each of the first containers to at least one second container, the hole of each second container is located at the bottom of each second container, the hole of the first container is located above the hole of the second container, and The holes are arranged in series, The fluid in the first container is guided to flow toward and through the holes of each first container and into the connected second container by the gas entering each first container through the gas inlet, and the holes of the second container allow the fluid flowing from each first container and through each second container to flow into the first container connected to the second container.

2. The reactor according to claim 1, wherein At least one of the holes of the first container is located at the top of the reactor.

3. A reactor according to any one of the preceding claims, wherein At least one of the holes of the first containers is a gap between a side wall of one of the first containers and a top of the reactor.

4. A reactor according to any one of the preceding claims, wherein At least one of the apertures of the first containers is a hole in a side wall of one of the first containers.

5. A reactor according to any one of the preceding claims, wherein At least one of the holes of the second container is located at the bottom of the reactor.

6. A reactor according to any one of the preceding claims, wherein At least one of the holes of the second containers is a gap between a side wall of one of the second containers and a bottom of the reactor.

7. A reactor according to any one of the preceding claims, wherein At least one of the apertures of the second containers is a hole in a side wall of one of the second containers.

8. A reactor according to any one of the preceding claims, wherein In at least one of the first containers, the gas inlet is located at the bottom of the container.

9. A reactor according to any one of the preceding claims, wherein Each of the first vessels is located between, in direct contact with, and connected to two second vessels such that a fluid flowing through the reactor moves through the vessels in a circular motion.

10. A reactor according to any preceding claim, further comprising at least one gas outlet.

11. The reactor according to claim 10, wherein The gas outlet is located in the reactor or at the top of the reactor.

12. A reactor according to any one of the preceding claims, wherein At least one of the first vessels also includes at least one product outlet.

13. The reactor according to claim 12, wherein The product outlet is located at the top of the first container.

14. The reactor according to claim 12 or 13, wherein The weir is configured to retain fluid in the reactor and allow product to enter the product outlet of the first vessel.

15. A reactor according to any one of the preceding claims, wherein At least one of the second vessels further comprises at least one product outlet.

16. The reactor according to claim 15, wherein The product outlet is located at the top of the second container.

17. The reactor according to claim 15 or 16, wherein The weir is configured to retain fluid in the reactor and allow product to enter the product outlet of the second vessel.

18. A method of reacting a fluid with a gas to produce a solid product, the method comprising: · Providing a reactor according to any one of the preceding claims, wherein the reactor comprises a fluid in a first container (container A); Introducing a reactive gas for mixing and reacting with a fluid into container A so that the gas passes through the fluid and directs the fluid-gas mixture to flow toward and through the apertures of container A and into a connected second container (container B), wherein the apertures of container B allow the fluid flowing from container A through container B to flow to another first container (container C); Introducing a second gas into container C, which directs the fluid-gas mixture toward and through the apertures of container C and into a connected second container (container D), wherein the apertures of container D allow the fluid flowing from container C through container D to flow back into container A; • Collect the solid product from the product outlet.

19. The method according to claim 18, wherein: The fluid is selected from molten metal, molten salt, molten alloy or a combination thereof.

20. The method according to claim 19, wherein: The fluid is a molten catalyst.

21. The method according to any one of claims 18 to 20, wherein: The reaction gas is natural gas.

22. The method according to any one of claims 18 to 21, wherein: The reaction gas includes methane.

23. The method according to any one of claims 18 to 22, wherein: The solid product is carbon.

24. The method according to any one of claims 18 to 23, wherein: The second gas is an inert gas.

Images