Small high-integration methanol-to-hydrogen reactor

Abstract

The invention provides a small high-integration methanol hydrogen production reactor which comprises a shell and a reaction tube arranged in the shell, an oxidation reactor is arranged at the front end of the reaction tube, a heat exchange mechanism is arranged between the shell and the reaction tube, and the heat exchange mechanism comprises multiple layers of heat exchange runners wrapping the reaction tube and / or the oxidation reactor. And the multiple layers of heat exchange runners are used for heating and vaporizing methanol on the hydrogen production side by recovering heat of the oxidation reactor, flue gas and hydrogen, and comprise multiple stages of methanol heating and vaporizing runners, multiple stages of flue gas heat supply runners and multiple stages of hydrogen cooling runners. The single-reaction-tube shell-and-tube structure is adopted, the volume is small, the structure is compact, the device is suitable for various scenes needing to be arranged in a limited or irregular space or needing small hydrogen production amount, diversified market requirements are met, standardized and serialized products are formed, and large-scale production and flexible application are facilitated.

Description

Technical Field

[0001] This invention relates to the field of methanol-to-hydrogen equipment technology, and in particular to a small, highly integrated methanol-to-hydrogen reactor. Background Technology

[0002] With the increasing urgency of clean energy needs in production and daily life, the application areas for methanol-to-hydrogen technology are constantly expanding. Along with the rapid development of new energy power systems, the integration of methanol-to-hydrogen equipment with fuel cells, as a continuous power supply module within these systems, has become a research hotspot in industry and academia in recent years. With technological advancements and evolving needs, there are higher requirements for the miniaturization, lightweighting, and efficiency of methanol reforming equipment.

[0003] However, existing methanol-to-hydrogen equipment has a complex structure, numerous pipeline connections, and a large overall size, making it difficult to install and use in limited or irregular spaces, thus restricting its application scope. Furthermore, most existing methanol-to-hydrogen equipment is custom-designed, lacking standardization and serialization, which hinders large-scale production and widespread application. It also makes it difficult to flexibly adjust and combine equipment according to the hydrogen production capacity and spatial distribution requirements of different application scenarios, failing to meet diverse market demands.

[0004] In addition, during the hydrogen production process, a large amount of heat carried by hydrogen and flue gas is not fully utilized, resulting in energy waste. Summary of the Invention

[0005] The present invention aims to provide a small, highly integrated methanol-to-hydrogen reactor to overcome the shortcomings of the prior art.

[0006] To solve the above-mentioned technical problems, the technical solution of the present invention is: a small, highly integrated methanol-to-hydrogen reactor, comprising a shell and a reaction tube disposed within the shell, an oxidation reactor being disposed at the front end of the reaction tube, a reaction flow channel being disposed inside the reaction tube, and a heat exchange mechanism being disposed between the shell and the reaction tube, the heat exchange mechanism comprising multiple layers of heat exchange flow channels covering the outside of the reaction tube and / or the oxidation reactor, the multiple layers of heat exchange flow channels heating and vaporizing methanol on the hydrogen production side by recovering heat from the oxidation reactor, flue gas and hydrogen, including multi-stage methanol heating and vaporization flow channels, multi-stage flue gas heating flow channels and multi-stage hydrogen cooling flow channels.

[0007] Furthermore, in the aforementioned small-scale, highly integrated methanol-to-hydrogen reactor, the methanol heating and vaporization channel includes heating channel one, heating channel four, and heating channel five arranged sequentially from the outside to the inside. Heating channel one, heating channel four, and heating channel five are annular channels arranged concentrically with the reaction tube. The first end of heating channel one is provided with a methanol inlet on the hydrogen production side, and the end of heating channel five is provided with multiple circumferentially distributed guide pipes. The multiple guide pipes connect the reaction tube and heating channel five.

[0008] Furthermore, in the aforementioned small, highly integrated methanol-to-hydrogen reactor, multiple guide pipes extend from the main heating channel of the flue gas into the reaction tube. The multiple guide pipes are located near the end panel at the front end of the reaction tube. The rear end of the oxidation reactor is provided with a conical connecting end cover, and a guide cavity is provided between the connecting end cover and the front end of the reaction tube.

[0009] Furthermore, in the aforementioned small-scale, highly integrated methanol-to-hydrogen reactor, the methanol heating and vaporization channel further includes heating channel two and heating channel three located outside the oxidation reactor. Heating channel two is a spiral tube that spirals around the outside of the oxidation reactor, and heating channel three is an annular channel located outside heating channel two. Methanol from the hydrogen production side sequentially enters the reaction tube through the methanol inlet on the hydrogen production side, heating channel one, heating channel two, heating channel three, heating channel four, heating channel five, and the guide pipe.

[0010] Furthermore, in the aforementioned small, highly integrated methanol-to-hydrogen reactor, heating channels one and four both extend from the rear end of the reaction tube to the front end of the oxidation reactor. Heating channels three and five are arranged in a ring along the same outer diameter and are isolated from each other by a separating ring located between them.

[0011] Furthermore, in the aforementioned small-scale, highly integrated methanol-to-hydrogen reactor, the flue gas heating channel includes an annular channel arranged sequentially from the inside out: heating channel one, heating channel two, and heating channel three. Heating channel one is the main heating channel located near the reaction tube and communicates with the rear end of the oxidation reactor. Heating channel two is located inside heating channel four, and heating channel three is located inside heating channel one. Each channel has a flue gas exhaust port at its end.

[0012] Furthermore, in the aforementioned small, highly integrated methanol-to-hydrogen reactor, the heating channel is equipped with a spiral baffle plate surrounding the outer wall of the reaction tube.

[0013] Furthermore, in the aforementioned small-scale, highly integrated methanol-to-hydrogen reactor, the hydrogen cooling channel includes sequentially arranged annular channels: cooling channel one, cooling channel two, and cooling channel three. Cooling channel one is connected to the hydrogen outlet at the rear end of the reaction tube and is located between heating channel one and heating channel five. Cooling channel two is located outside the oxidation reactor and is located between heating channel two and heating channel three. Cooling channel three is located outside the heating channel one, and a hydrogen exhaust port is provided at the end of cooling channel three.

[0014] Furthermore, in the aforementioned small-scale, highly integrated methanol-to-hydrogen reactor, the multiple heat exchange channels are separated by multiple annular flow channel plates. Each annular flow channel plate has an end plate at its rear end and a connecting plate at its front end. Both the end plates and the connecting plate have multiple flow channel openings for connecting or isolating the corresponding heat exchange channels. A second connecting plate is provided between the end plates and the first connecting plate, and this second connecting plate is fitted onto the rear end of the oxidation reactor. This second connecting plate also has multiple flow channel openings for connecting or isolating the corresponding heat exchange channels. Preferably, a detachable end cover is provided at the middle of the rear end of each end plate. This end cover can seal the rear end of the reaction tube and serves as a disassembly / removal port for the catalyst carrier, facilitating the disassembly and reassembly of the catalyst carrier.

[0015] Furthermore, in the aforementioned small, highly integrated methanol-to-hydrogen reactor, the front end of the oxidation reactor is provided with a mixing end cover. The mixing end cover is provided with an air inlet and multiple oxidation-side methanol inlets. The air inlet is located at the front end of the mixing end cover, and the multiple oxidation-side methanol inlets are evenly arranged on the outside of the mixing end cover. A dividing plate is provided between the air inlet and the oxidation-side methanol inlet, and a protective cover connected to the shell is provided on the outside of the mixing end cover.

[0016] Furthermore, in the aforementioned small, highly integrated methanol-to-hydrogen reactor, the inner wall of the reaction tube is provided with multiple spiral grooves, and each spiral groove is provided with multiple protruding micro-protrusions, the micro-protrusions not higher than the inner wall of the reaction tube.

[0017] Furthermore, in the aforementioned small, highly integrated methanol-to-hydrogen reactor, the depth of the spiral groove is 0.2-1 mm, and the pitch is 5-15 mm.

[0018] Furthermore, in the aforementioned small, highly integrated methanol-to-hydrogen reactor, multiple micro-protrusions are arranged in an array within a spiral groove. Preferably, the spiral groove contains multiple rows of micro-protrusions arranged in an array along the spiral direction of the groove, with adjacent rows of micro-protrusions interleaved.

[0019] Furthermore, in the aforementioned small, highly integrated methanol-to-hydrogen reactor, the outer wall of the reaction tube is provided with multiple fins. These fins are arranged in an array along the axial direction of the tube, or are evenly arranged around the circumference of the outer wall of the tube, or are spirally distributed on the outer wall of the tube.

[0020] Furthermore, in the aforementioned small-scale, highly integrated methanol-to-hydrogen reactor, a catalyst support is provided inside the reaction tube. The catalyst support is a cylindrical structure made of woven and wound metal wires, which are made of iron-chromium-aluminum metal wires with a diameter of 0.2-0.5 mm.

[0021] Furthermore, in the aforementioned small-scale, highly integrated methanol-to-hydrogen reactor, the porosity of the catalyst support ranges from 80% to 90%, and the porosity of the catalyst support gradually decreases from the inside to the outside along the cross-section of the catalyst support.

[0022] Furthermore, in the aforementioned small-scale, highly integrated methanol-to-hydrogen reactor, the catalyst support comprises multiple sets of abutting support groups, which are arranged axially along the reaction tube.

[0023] Furthermore, in the aforementioned small-scale, highly integrated methanol-to-hydrogen reactor, each of the carrier groups includes at least one sub-carrier, and the porosity of each carrier group gradually increases along the reaction direction within the reaction tube.

[0024] The present invention also provides a hydrogen production module, comprising a plurality of the above-described methanol-to-hydrogen reactors, wherein the plurality of methanol-to-hydrogen reactors are connected in parallel.

[0025] Compared with the prior art, the beneficial effects of the present invention are: This invention employs a single-reaction tube shell-and-tube structure, resulting in a small size and compact structure. Based on 0.5 Nm... 3 / h、1 Nm 3 / h、2Nm 3 / h、5 Nm 3 Four hydrogen production capacity specifications per hour were developed, and four standardized small hydrogen production reactors were manufactured. Through combination and assembly, these reactors can basically cover the range of 0.5~20 Nm³. 3 It meets various hydrogen production needs within a certain range (e.g., per hour), suitable for scenarios requiring layout in limited or irregular spaces or with small hydrogen production needs. It satisfies diverse market demands, has formed standardized and serialized products, facilitates large-scale production and flexible application, and enhances market competitiveness.

[0026] The heat exchange mechanism of this invention adopts a multi-layer integrated design, which reduces pipeline connections, makes the reactor structure more compact, smaller in size and lighter in weight, improves the integration and reliability of the equipment, and adapts to the application requirements of confined spaces; and through the efficient multi-pass utilization of hydrogen and flue gas, it realizes the full recovery and reuse of heat in the system, significantly improves heat transfer efficiency, increases reaction rate, increases hydrogen production efficiency, and effectively reduces energy consumption.

[0027] The reaction-side structure (spiral groove and micro-protrusion) of the reaction tube of the present invention can increase the heat transfer area, improve flow uniformity, and increase hydrogen production efficiency, while the fin structure on the heating side of the reaction tube increases the contact time between hot flue gas and the tube wall, increases the heat transfer area, and improves heat exchange efficiency.

[0028] The catalyst support of the present invention achieves a gradient pore distribution in both the cross-section and length direction, thereby solving the problem caused by temperature difference in the cross-section and length direction, reducing the amount of catalyst used, and saving costs.

[0029] Each methanol-to-hydrogen reactor in the hydrogen production module of this invention can be controlled independently and adjusted uniformly through the overall system. Reactors of different specifications can be flexibly combined and used according to different application scenarios to achieve precise control and optimized operation of hydrogen production, and it has strong flexibility and adaptability. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of the external structure of the small, highly integrated methanol-to-hydrogen reactor of the present invention. Figure 2 This is a schematic diagram of the half-section structure of the small, highly integrated methanol-to-hydrogen reactor of the present invention. Figure 1 ; Figure 3 This is a schematic diagram of the half-section structure of the small, highly integrated methanol-to-hydrogen reactor of the present invention. Figure 2 ; Figure 4 for Figure 3 A partial enlarged structural diagram of A; Figure 5 for Figure 3 A magnified schematic diagram of the B-section structure; Figure 6 This is a schematic diagram of the connecting plate two structure of the small, highly integrated methanol-to-hydrogen reactor of the present invention. Figure 7 This is a schematic diagram of the reaction tube structure of the small, highly integrated methanol-to-hydrogen reactor of the present invention. Figure 1 ; Figure 8 for Figure 7 A magnified schematic diagram of the C-section structure; Figure 9 This is a schematic diagram of the reaction tube structure of the small, highly integrated methanol-to-hydrogen reactor of the present invention. Figure 2 ; Figure 10 This is a schematic diagram of the catalyst support structure of the small, highly integrated methanol-to-hydrogen reactor of the present invention. Figure 11This is a schematic cross-sectional view of the catalyst support for the small, highly integrated methanol-to-hydrogen reactor of the present invention. Figure 12 This is a schematic diagram of the hydrogen production module of the present invention; In the diagram: 100, methanol-to-hydrogen reactor; 1. Shell; 2. Reaction tube; 21. Spiral groove; 22. Micro-protrusion; 23. Fin; 3. Oxidation reactor; 31. Connecting end cap; 4. Methanol heating and vaporization flow channel; 41. Heating flow channel one; 42. Heating flow channel two; 43. Heating flow channel three; 44. Heating flow channel four; 45. Heating flow channel five; 46. Methanol inlet on the hydrogen production side; 47. Guide pipe; 48. Separator ring; 5. Flue gas heating channel; 51. Heating channel one; 52. Heating channel two; 53. Heating channel three; 54. Flue gas exhaust port; 55. Spiral baffle; 6. Hydrogen cooling channel; 61. Cooling channel one; 62. Cooling channel two; 63. Cooling channel three; 64. Hydrogen exhaust port; 71. Annular flow channel plate; 72. End plate; 73. Connecting plate one; 74. Connecting plate two; 75. End cover plate 8. Mixing end cover; 81. Air inlet; 82. Oxidation-side methanol inlet; 83. Equalization plate; 84. Protective cover; 9. Catalyst support. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] Example 1 like Figure 1-11As shown, a small, highly integrated methanol-to-hydrogen reactor includes a shell 1 and a reaction tube 2 disposed within the shell 1. An oxidation reactor 3 is located at the front end of the reaction tube 2. The reaction tube 2 contains a reaction flow channel. A heat exchange mechanism is provided between the shell 1 and the reaction tube 2. The heat exchange mechanism includes multiple layers of heat exchange channels covering the outside of the reaction tube 2 and / or the oxidation reactor 3. These multiple heat exchange channels heat and vaporize the methanol on the hydrogen production side by recovering heat from the oxidation reactor 3, flue gas, and hydrogen. The mechanism includes multi-stage methanol heating and vaporization channels 4, multi-stage flue gas heating channels 5, and multi-stage hydrogen cooling channels 6, wherein the flue gas is a high-temperature gas produced by the oxidation reaction in the oxidation reactor 3. The hydrogen production reactor of this invention adopts a shell-and-tube structure with a single reaction tube, resulting in a small volume and compact structure. It separates the hydrogen production reaction and the oxidation heating process, improving heat transfer efficiency and reaction control flexibility.

[0034] like Figure 2-5 As shown, the methanol heating and vaporization channel 4 includes heating channel 1 41, heating channel 44, and heating channel 5 45 arranged sequentially from the outside to the inside. Heating channel 1 41, heating channel 44, and heating channel 5 45 are annular channels arranged concentrically with the reaction tube 2. The first end of heating channel 1 41 is provided with a methanol inlet 46 on the hydrogen production side. The end of heating channel 5 45 is provided with multiple guide pipes 47 evenly distributed around the circumference. The multiple guide pipes 47 connect the reaction tube 2 and heating channel 5 45, guiding the vaporized methanol vapor into the reaction tube.

[0035] Multiple guide pipes 47 extend from the main heating channel of the flue gas into the reaction tube 2. The main heating channel of the flue gas is the heating channel 51. The multiple guide pipes 47 are set near the end panel of the front end of the reaction tube 2. The rear end of the oxidation reactor 3 is provided with a conical connecting end cover 31. A guide cavity is formed between the connecting end cover 31 and the front end of the reaction tube 2, which can quickly reheat the vaporized methanol before it enters the reaction tube 2, ensuring that the methanol reaches the reaction temperature.

[0036] like Figure 2-5 As shown, the methanol heating and vaporization channel 4 also includes heating channel two 42 and heating channel three 43 located outside the oxidation reactor 3. Heating channel two 42 is located close to the outer shell of the oxidation reactor 3 and is a spiral tube that spirals around the outside of the oxidation reactor 3. Heating channel three 43 is an annular channel located outside heating channel two 42. Methanol from the hydrogen production side enters the reaction tube sequentially through the hydrogen production side methanol inlet 46, heating channel one 41, heating channel two 42, heating channel three 43, heating channel four 44, heating channel five 45, and guide pipe 47. The methanol in heating channels two 42 and heating channel three 43 can absorb most of the heat from outside the oxidation reactor, which can reduce the external temperature of the oxidation reactor and accelerate the vaporization of methanol.

[0037] Heating channels 1 (41) and 44 (44) extend from the rear end of reaction tube 2 to the front end of oxidation reactor 3. Heating channels 3 (43) and 5 (45) are arranged in a ring along the same outer diameter and are isolated from each other by a separating ring 48 located between them. Methanol on the hydrogen production side is typically heated through heating channels 1 (41), 2 (42), and 3 (43), then vaporized in heating channel 4 (44), and further heated in heating channel 5 (45) and the guide cavity. This allows the methanol vapor to quickly reach the optimal reaction temperature range before contacting the catalyst, promoting rapid reforming.

[0038] like Figure 2-5 As shown, the flue gas heating channel 5 includes annular channels arranged sequentially from the inside to the outside: heating channel one 51, heating channel two 52, and heating channel three 53. Heating channel one 51 is the main heating channel located near the reaction tube 2 and is connected to the rear end of the oxidation reactor 3, i.e., connected to the guide cavity. Heating channel one 51 is provided with a spiral baffle 55 arranged around the outer wall of the reaction tube 2. The spiral baffle 55 can extend the heating time of the reaction tube 2 by heating channel one 51, so that the reaction in the reaction tube is more complete, thereby improving the hydrogen production efficiency. Heating channel two 52 is located inside the heating channel four 44, and heating channel three 53 is located inside the heating channel one 41. Its end is provided with a flue gas exhaust port 54. Heating channels two 52 and three 53 are mainly used to heat the methanol on the hydrogen production side.

[0039] like Figure 2-5 As shown, the hydrogen cooling channel 6 includes three sequentially arranged annular channels: cooling channel one 61, cooling channel two 62, and cooling channel three 63. Cooling channel one 61 is connected to the hydrogen outlet at the rear end of the reaction tube 2 and is located between heating channel one 51 and heating channel five 45. Cooling channel two 62 is located outside the oxidation reactor 3, between heating channel two 42 and heating channel three 43. Cooling channel three 63 is located outside heating channel one 51 and is the outermost layer of the multi-layer heat exchange channel. A hydrogen exhaust port 64 is located at the end of cooling channel three 63. Cooling channel one 61 and cooling channel two 62 are arranged side-by-side in a ring with the same outer diameter and are connected by connecting plate two 74. Hydrogen is a gas mainly composed of hydrogen produced by the methanol-to-hydrogen reactor. The hydrogen cooling channel 6 not only heats the methanol and recovers the heat from hydrogen production, saving energy, but also rapidly reduces the temperature of the hydrogen.

[0040] like Figure 2-5As shown, the multi-layer heat exchange channels are arranged sequentially from the outside to the inside, that is, along the direction closest to the reaction tube 2: cooling channel 3 63, heating channel 1 41, heating channel 3 53, heating channel 44, heating channel 2 52, heating channel 55, cooling channel 1 61, and heating channel 1 51. Among them, cooling channel 2 62 and cooling channel 1 61 are arranged side by side, and heating channel 3 43 and heating channel 5 45 are arranged side by side.

[0041] like Figure 2-6 As shown, the multi-layer heat exchange channels are separated by multiple annular flow channel plates 71. End plates 72 are provided at the rear ends of the multiple annular flow channel plates 71, and connecting plates 73 are provided at the front ends of the multiple annular flow channel plates 71. Multiple flow channel openings are provided on the end plates 72 and connecting plates 73 for connecting or isolating the corresponding heat exchange channels. The end plates 72 and connecting plates 73 can be assembled from multiple flat plates for easy processing of the flow channel openings. A connecting plate 74 is provided between the end plates 72 and connecting plates 73. The connecting plate 74 is fitted onto the rear end of the oxidation reactor 3 and also has multiple flow channel openings for connecting or isolating the corresponding heat exchange channels. Specifically, the connecting plate 74 connects heating channel 42 and heating channel 43, as well as cooling channel 61 and cooling channel 62, and isolates the methanol heating and vaporization channel 4 from the hydrogen cooling channel 6.

[0042] In addition, such as Figure 2 , 5 As shown, the end plate 72 has a detachable end cover plate 75 at the middle of its rear end. The end cover plate 75 can close the rear end of the reaction tube 2 and serves as the disassembly port for the catalyst carrier 9, making it easy to disassemble and assemble the catalyst carrier 9.

[0043] like Figure 1-2 As shown, the front end of the oxidation reactor 3 is provided with a mixing end cover 8. The mixing end cover 8 is provided with an air inlet 81 and multiple oxidation-side methanol inlets 82. The air inlet 81 is located at the front end of the mixing end cover 8, and the multiple oxidation-side methanol inlets 82 are evenly distributed on the outside of the mixing end cover 8. A distribution plate 83 is provided between the air inlet 81 and the oxidation-side methanol inlets 82 to make the air and the oxidation-side methanol mix more evenly. The outside of the mixing end cover 8 is provided with a protective cover 84 connected to the shell 1. The protective cover 84 has the same shape as the shell 1, making the overall appearance more beautiful. The protective cover 84 is provided with a clearance opening (not shown in the figure) for the oxidation-side methanol inlets 82 to pass through. The outside of the oxidation reactor 3 is provided with an electric heating power supply connection port.

[0044] This invention employs a single-reaction tube shell-and-tube structure, resulting in a small size and compact structure. Based on 0.5 Nm... 3 / h、1 Nm 3 / h、2Nm 3 / h、5 Nm 3Four hydrogen production capacity specifications per hour were developed, and four standardized small hydrogen production reactors were manufactured. By assembling reactors of the same or different specifications, the range of hydrogen production capacity from 0.5 to 20 Nm³ could be basically covered. 3 It meets various hydrogen production needs within a certain range (e.g., per hour), suitable for scenarios requiring layout in limited or irregular spaces or with small hydrogen production needs. It satisfies diverse market demands, has formed standardized and serialized products, facilitates large-scale production and flexible application, and enhances market competitiveness.

[0045] The heat exchange mechanism of this invention adopts a multi-layer integrated design, which reduces pipeline connections, makes the reactor structure more compact, smaller in size and lighter in weight, improves the integration and reliability of the equipment, and adapts to the application requirements of confined spaces; and through the efficient multi-pass utilization of hydrogen and flue gas, it realizes the full recovery and reuse of heat in the system, significantly improves heat transfer efficiency, increases reaction rate, increases hydrogen production efficiency, and effectively reduces energy consumption.

[0046] Furthermore, the core part of the small, highly integrated hydrogen production reactor of the present invention is mainly cylindrical in shape, but can be designed as square according to the needs of specific application scenarios.

[0047] Example 2 Based on the structure of Example 1, such as Figure 7-9 As shown, the inner side of the reaction tube 2 is the reaction side, i.e., the reaction space between the catalyst and methanol, and the outer side of the reaction tube 2 is the flue gas heating side. The inner wall of the reaction tube 2 is provided with multiple spiral grooves 21, which are recessed towards the outer side of the reaction tube 2. Each spiral groove 21 is provided with multiple protruding micro-protrusions 22. The micro-protrusions 22 are not higher than the inner wall of the reaction tube 2 and do not encroach on the flow section inside the tube.

[0048] like Figure 8 As shown, the spiral groove 2 is arc-shaped with a depth of 0.2-1mm and a pitch of 5-15mm.

[0049] like Figure 7 , 9 As shown, multiple micro-protrusions 22 are arranged in an array within the spiral groove 21. Specifically, the spiral groove 21 has multiple rows of micro-protrusions 22 arranged in an array along the spiral direction of the spiral groove 21, with adjacent rows of micro-protrusions 22 interleaved. The spacing between adjacent micro-protrusions 22 is 0.2-5 mm. The spacing between micro-protrusions 22 differs along the arc direction and the spiral direction of the spiral groove 21. Specifically, along the arc direction of the spiral groove 21, the spacing between adjacent micro-protrusions 22 is 0.2-2 mm, and along the spiral direction of the spiral groove 21, the spacing between adjacent micro-protrusions 22 is 2-5 mm.

[0050] The micro-protrusion 22 is cylindrical or elliptical. Specifically, the height of the micro-protrusion 22 is 0.1-0.5 mm, and the outer diameter is 0.1-1 mm.

[0051] The spiral grooves 21 significantly increase the inner surface area of ​​the reaction tube 2, thereby increasing the heat exchange area. This allows the heat transferred by the hot flue gas to more fully contact the reactants inside the tube, thus improving heat exchange efficiency. Furthermore, as the reactants flow within the tube, the spiral grooves 21 turbulently move the fluid, creating a spiral flow that disrupts the fluid boundary layer and increases the contact opportunities between the fluid and the tube wall, further enhancing heat exchange efficiency. Simultaneously, this spiral flow also ensures a more uniform distribution of reactants within the tube, preventing incomplete localized reactions.

[0052] The micro-protrusions 22 located within the spiral grooves 21 further increase the effective heat exchange area, increase the contact area between the reactants (methanol vapor) and the catalyst, and improve the reaction efficiency. Furthermore, the micro-protrusions 22 have a certain obstructing and guiding effect on the fluid, which can regulate the fluid velocity and direction, making the fluid more evenly distributed within the pipe and reducing flow dead zones and localized overheating.

[0053] To further improve heat exchange efficiency, such as Figure 7-9 As shown, the outer wall of the reaction tube 2 is provided with multiple fins 23. The cross-section of the fins 23 is arc-shaped, square, or trapezoidal, and the height of the fins 23 is 0.2-5mm. The fins 23 can increase the contact area between the reaction tube 2 and the hot flue gas, thereby improving the heat transfer rate.

[0054] Multiple fins 23 are evenly arranged on the outer wall of the reaction tube 2. There are several arrangement methods, including: array arrangement along the axial direction of the reaction tube 2, even arrangement along the circumference of the outer wall of the reaction tube 2, or spiral distribution on the outer wall of the reaction tube 2; the spacing between adjacent fins is 5-15 mm. In the array arrangement along the axial direction of the tube body 1, the fins are in annular shape, such as... Figure 7 As shown, fins 23 are spirally distributed on the outer wall of reaction tube 2, such as... Figure 9 As shown, the fins 23 are evenly arranged along the circumference of the outer wall of the reaction tube 2. In order to ensure the installation of the spiral baffle 55, the fins 23 are provided with slots for the spiral baffle 55 to pass through.

[0055] The reaction-side structure (spiral grooves and micro-protrusions) of the reaction tube 2 of this invention increases the heat transfer area, improves flow uniformity, and enhances hydrogen production efficiency. Meanwhile, the finned structure on the heating side of the reaction tube increases the contact time between the hot flue gas and the tube wall, further increasing the heat transfer area and improving heat exchange efficiency. Compared to conventional reaction tubes, the heat exchange efficiency can be increased by 30%-50%, the methanol conversion rate by 15%-25%, and the hydrogen production yield by 30%-50%. Simultaneously, it can reduce the amount of catalyst used, lowering production costs.

[0056] Example 3 Based on the structure of Embodiment 1 or Embodiment 2, such as Figure 2 , 10 As shown in Figure -11, the reaction tube 2 contains a catalyst carrier 9, which is a cylindrical structure made of woven and wound metal wires. The metal wires are made of iron-chromium-aluminum metal with a diameter of 0.2-0.5 mm. The metal wires are first woven into a metal mesh with a weaving angle of 30°-60° and square or diamond-shaped mesh openings. Then, the metal mesh is wound into a cylindrical structure.

[0057] The porosity of the catalyst support 9 ranges from 80% to 90%, and the porosity of the catalyst support 9 gradually decreases from the inside to the outside along the cross-section of the catalyst support 9. The larger the porosity, the looser the support structure. The porosity distribution in the cross-section corresponds to the decrease in temperature from the outside to the inside, and the reduction of catalytic reaction.

[0058] like Figure 2 As shown, the catalyst support 9 comprises multiple sets of abutting support groups, which are arranged along the axial direction of the reaction tube. That is, each set of support groups has the same outer diameter but different lengths.

[0059] Each support group includes at least one sub-support. The sub-supports in each support group have the same porosity. The number of sub-supports and the number of support groups can be flexibly adjusted according to the hydrogen production rate and the size of the reaction tube. Since different hydrogen production rates require reaction tubes of different sizes, the catalyst support is manufactured into standardized sub-supports, which are then assembled into suitable catalyst supports. This method offers good flexibility and facilitates mass production.

[0060] Furthermore, along the reaction direction within reaction tube 2, the porosity of each support group gradually increases. Corresponding to the front-to-back direction (i.e., the reaction direction within the reaction tube), the temperature decreases, the catalytic reaction decreases, and the catalyst requirement decreases. Specifically, the outermost layer porosity of each support group increases sequentially, ranging from 80-86%, while the innermost layer porosity is ≤90%. During installation, the supports are sequentially placed into the reaction tube 2 from front to back, according to the order of increasing outermost layer porosity. This achieves a gradient pore distribution in both the cross-section and length directions, thereby mitigating the effects of temperature differences in the cross-section and length directions, reducing catalyst usage, and saving costs.

[0061] Example 4 like Figure 12 As shown, the present invention also provides a hydrogen production module, including multiple methanol-to-hydrogen reactors 100 as described above, wherein the multiple methanol-to-hydrogen reactors 100 are connected in parallel.

[0062] Each methanol-to-hydrogen reactor 100 in the hydrogen production module can be controlled independently, with its feed rate, reaction temperature, pressure and other parameters controlled independently. It can also be uniformly adjusted through the overall system. Different specifications of reactors can be flexibly combined and used according to different application scenarios to achieve precise control and optimized operation of hydrogen production, which has strong flexibility and adaptability.

[0063] For example, in a hydrogen fuel cell vehicle, hydrogen needs to be supplied to the fuel cell. Due to the limited space inside the vehicle, multiple reactors of different sizes are combined, such as in a 5+5+2+2 configuration. These reactors are compactly installed in specific locations within the vehicle, and each reactor is centrally controlled by a central system. The hydrogen production rate is adjusted in real time according to the vehicle's driving conditions and hydrogen demand. In actual operation, this hydrogen production system can stably supply hydrogen to the fuel cell, and because the reactors are small in size and lightweight, their impact on the overall performance of the vehicle is minimal.

[0064] For example, in a distributed energy station, a large amount of hydrogen needs to be produced for power generation. Based on the spatial layout of the energy station and the hydrogen production requirements, multiple large-scale reactors were selected and combined. Through a reasonable layout and optimized control strategy, the reactors work collaboratively, achieving efficient and stable hydrogen production operation. This hydrogen production system can make full use of the space within the energy station, and its high flexibility facilitates the integrated arrangement of hydrogen production modules and fuel cell modules, reducing energy consumption and improving energy utilization efficiency.

[0065] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0066] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A small, highly integrated methanol-to-hydrogen reactor, characterized in that: The device includes a shell and a reaction tube disposed within the shell. An oxidation reactor is located at the front end of the reaction tube. A reaction flow channel is located inside the reaction tube. A heat exchange mechanism is provided between the shell and the reaction tube. The heat exchange mechanism includes multiple layers of heat exchange flow channels covering the outside of the reaction tube and / or the oxidation reactor. The multiple layers of heat exchange flow channels heat and vaporize methanol on the hydrogen production side by recovering heat from the oxidation reactor, flue gas, and hydrogen. The mechanism includes multi-stage methanol heating and vaporization flow channels, multi-stage flue gas heating flow channels, and multi-stage hydrogen cooling flow channels.

2. The small, highly integrated methanol-to-hydrogen reactor according to claim 1, characterized in that: The methanol heating and vaporization flow channel includes heating flow channel one, heating flow channel four, and heating flow channel five arranged sequentially from the outside to the inside. Heating flow channel one, heating flow channel four, and heating flow channel five are annular flow channels arranged concentrically with the reaction tube. The first end of heating flow channel one is provided with a methanol inlet on the hydrogen production side, and the end of heating flow channel five is provided with multiple guide pipes evenly distributed around the circumference. The multiple guide pipes connect the reaction tube and heating flow channel five.

3. The small, highly integrated methanol-to-hydrogen reactor according to claim 2, characterized in that: Multiple guide pipes extend from the main heating channel of the flue gas into the reaction tube. The multiple guide pipes are located near the end panel at the front end of the reaction tube. The rear end of the oxidation reactor is provided with a conical connecting end cover. A guide cavity is provided between the connecting end cover and the front end of the reaction tube.

4. The small, highly integrated methanol-to-hydrogen reactor according to claim 2 or 3, characterized in that: The methanol heating and vaporization flow channel also includes heating flow channel two and heating flow channel three located outside the oxidation reactor. Heating flow channel two is a spiral tube that spirals around the outside of the oxidation reactor. Heating flow channel three is an annular flow channel located outside heating flow channel two. Methanol from the hydrogen production side enters the reaction tube sequentially through the methanol inlet on the hydrogen production side, heating flow channel one, heating flow channel two, heating flow channel three, heating flow channel four and heating flow channel five, and the guide pipe.

5. The small, highly integrated methanol-to-hydrogen reactor according to claim 4, characterized in that: Heating channel one and heating channel four both extend from the rear end of the reaction tube to the front end of the oxidation reactor. Heating channel three and heating channel five are arranged in a ring along the same outer diameter and are isolated from each other by a partition ring provided between heating channel three and heating channel five.

6. The small, highly integrated methanol-to-hydrogen reactor according to claim 4, characterized in that: The flue gas heating channel includes annular channels arranged sequentially from the inside to the outside: heating channel one, heating channel two, and heating channel three. Heating channel one is the main heating channel located near the reaction tube and is connected to the rear end of the oxidation reactor. Heating channel two is located inside heating channel four, and heating channel three is located inside heating channel one. Each channel has a flue gas exhaust port at its end.

7. The small, highly integrated methanol-to-hydrogen reactor according to claim 6, characterized in that: The heating channel is equipped with a spiral baffle plate that surrounds the outer wall of the reaction tube.

8. The small, highly integrated methanol-to-hydrogen reactor according to claim 6, characterized in that: The hydrogen cooling channel includes annular channels arranged in sequence: cooling channel one, cooling channel two, and cooling channel three. Cooling channel one is connected to the hydrogen outlet at the rear end of the reaction tube and is located between heating channel one and heating channel five. Cooling channel two is located outside the oxidation reactor and is located between heating channel two and heating channel three. Cooling channel three is located outside the heating channel one. A hydrogen exhaust port is provided at the end of cooling channel three.

9. The small, highly integrated methanol-to-hydrogen reactor according to claim 1, characterized in that: The multi-layered heat exchange channels are separated by multiple annular flow channel plates. The rear end of the multiple annular flow channel plates is provided with an end plate, and the front end of the multiple annular flow channel plates is provided with a connecting plate. The end plate and the connecting plate are provided with multiple flow channel openings for connecting or isolating the corresponding heat exchange channels. A connecting plate is provided between the end plate and the connecting plate. The connecting plate is sleeved at the rear end of the oxidation reactor. The connecting plate is also provided with multiple flow channel openings for connecting or isolating the corresponding heat exchange channels.

10. The small, highly integrated methanol-to-hydrogen reactor according to claim 1, characterized in that: The front end of the oxidation reactor is provided with a mixing end cover, which is provided with an air inlet and multiple oxidation-side methanol inlets. The air inlet is located at the front end of the mixing end cover, and the multiple oxidation-side methanol inlets are evenly distributed on the outside of the mixing end cover. A distribution plate is provided between the air inlet and the oxidation-side methanol inlet, and a protective cover connected to the shell is provided on the outside of the mixing end cover.

11. The small, highly integrated methanol-to-hydrogen reactor according to claim 1, characterized in that: The inner wall of the reaction tube is provided with a plurality of spiral grooves, and each spiral groove is provided with a plurality of protruding micro-protrusions, the micro-protrusions being no higher than the inner wall of the reaction tube.

12. The small, highly integrated methanol-to-hydrogen reactor according to claim 11, characterized in that: The depth of the spiral groove is 0.2-1mm, and the pitch is 5-15mm.

13. The small, highly integrated methanol-to-hydrogen reactor according to claim 11, characterized in that: Multiple micro-protrusions are arranged in an array within a spiral groove.

14. The small, highly integrated methanol-to-hydrogen reactor according to claim 11, characterized in that: The outer wall of the reaction tube is provided with multiple fins, which are arranged in an array along the axial direction of the tube, or evenly arranged around the circumference of the outer wall of the tube, or spirally distributed on the outer wall of the tube.

15. The small, highly integrated methanol-to-hydrogen reactor according to claim 1 or 11, characterized in that: The reaction tube contains a catalyst carrier, which is a cylindrical structure made of woven and wound metal wires. The metal wires are made of iron-chromium-aluminum metal wires with a diameter of 0.2-0.5 mm.

16. The small, highly integrated methanol-to-hydrogen reactor according to claim 15, characterized in that: The porosity of the catalyst support is in the range of 80-90%, and the porosity of the catalyst support gradually decreases from the inside to the outside along the cross-section of the catalyst support.

17. The small, highly integrated methanol-to-hydrogen reactor according to claim 16, characterized in that: The catalyst support comprises multiple sets of abutting support groups, which are arranged axially along the reaction tube.

18. The small, highly integrated methanol-to-hydrogen reactor according to claim 17, characterized in that: Each of the carrier groups includes at least one sub-carrier, and the porosity of each of the carrier groups gradually increases along the reaction direction within the reaction tube.

19. A hydrogen production module, characterized in that: It includes multiple small, highly integrated methanol-to-hydrogen reactors as described in any one of claims 1-18, wherein the multiple methanol-to-hydrogen reactors are connected in parallel.

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