Heat management system for catalytic reactor

Abstract

A reactor and method of operation are described herein. In certain methods, the reactor includes one or more first zones in thermal communication with one or more second zones. The one or more first zones define a reaction domain and include a catalyst bed. The one or more second zones define a thermal diffusion domain and include one or more vapor chambers. In certain embodiments, the one or more first zones and the one or more second zones are integrally formed. In certain embodiments, the reactor includes one or more third zones in thermal communication with the one or more first zones and / or the one or more second zones. The one or more third zones define a thermal management zone and contain a thermal management fluid.

Description

Technical Field

[0001] These teachings typically relate to catalytic reactors, and more specifically to the thermal management systems used in catalytic reactors. Background Technology

[0002] In the field of chemical manufacturing, catalytic reactors are commonly used to facilitate various chemical processes. In some methods, catalytic reactors can be used to produce syngas (a mixture of carbon monoxide and hydrogen) and sustainable aviation fuel (SAF). In these applications, maintaining the operating temperature of the catalytic reactor within a specific range is crucial to provide high conversion and selectivity, thereby contributing to the overall efficiency and sustainability of the production process. Therefore, a thermal management system for the catalytic reactor may be required. Attached Figure Description

[0003] The thermal management system for the catalytic reactor described in the following detailed description, especially when studied in conjunction with the accompanying drawings, at least partially meets various needs. This specification sets forth a complete and enabling disclosure of all aspects of this specification, including its best mode, to those skilled in the art, and references the accompanying drawings, in which:

[0004] Figure 1 Cross-sections of reactors according to various embodiments based on these teachings are shown;

[0005] Figure 2 Schematic diagrams of reactors according to various embodiments of these teachings are shown;

[0006] Figure 3 Schematic diagrams of reactors according to various embodiments of these teachings are shown;

[0007] Figure 4 Schematic diagrams of reactors according to various embodiments of these teachings are shown;

[0008] Figure 5 Schematic diagrams of reactors according to various embodiments of these teachings are shown;

[0009] Figure 6 Cross-sectional views of steam chambers according to various embodiments based on these teachings are shown;

[0010] Figure 7 Cross-sectional views of steam chambers according to various embodiments of these teachings are shown;

[0011] Figure 8 Cross-sectional views of steam chambers according to various embodiments of these teachings are shown;

[0012] Figure 9 Cross-sectional views of steam chambers according to various embodiments based on these teachings are shown;

[0013] Figure 10 ( Figure 10A and 10B The diagram shows a cross-sectional view of a steam chamber according to various embodiments of these teachings;

[0014] Figure 11 Cross-sectional views of steam chambers according to various embodiments based on these teachings are shown;

[0015] Figure 12 ( Figure 12A and Figure 12B The diagram shows cross-sectional views of reactors according to various embodiments of these teachings, and a perspective view showing the three-dimensional unit cells forming the reactor; and

[0016] Figure 13 ( Figure 13A , Figure 13B , Figure 13C The diagram shows cross-sections of reactors according to various embodiments based on these teachings.

[0017] The elements in the figures are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the size and / or relative position of some elements in the figures may be exaggerated relative to other elements to aid in understanding the various embodiments of this teaching. Furthermore, common but easily understood elements that are useful or necessary in commercially viable embodiments are generally not depicted to facilitate less obstructive observation of these various embodiments of this teaching. Certain actions and / or steps may be described or depicted in a specific sequence of occurrence, and those skilled in the art will understand that such specificity of sequence is not actually required. Detailed Implementation

[0018] The thermal management system for catalytic reactors described herein provides a method for controlling the temperature of catalytic reactors. More specifically, the method described herein utilizes one or more vapor chambers to minimize the thermal gradient formed in the catalyst bed, thereby improving catalytic reaction efficiency.

[0019] In catalytic reactors, catalysts exhibit a narrow temperature range within which they optimally release reaction products. Traditional reactor designs often experience large spatial and temporal temperature gradients within the catalyst bed, leading to deviations from the target operating temperature. For example, non-uniform temperature distributions can create hot and cold zones within the catalyst, resulting in catalyst deactivation, reduced reaction efficiency, and overall reactor performance degradation. Furthermore, these temperature gradients are typically managed through complex reactor flow designs and the associated high pumping power requirements to maintain the heating / cooling flow, increasing operating costs and complexity.

[0020] The method described herein advantageously provides a multi-domain reactor designed to reduce the occurrence of large spatial and temporal temperature gradients within the catalyst bed. In some configurations, the multi-domain reactor comprises a catalyst domain containing the catalyst bed and a thermal diffusion domain containing one or more vapor chambers. These vapor chambers operate via an evaporation-condensation cycle of the working fluid, providing a more uniform heat distribution within the catalyst bed, reducing thermal gradients, and maintaining the catalyst bed within the desired temperature range. This results in increased reaction efficiency and high product yields. Furthermore, the more uniform temperature distribution suppresses the formation of hot and cold zones, reducing the risk of catalyst damage and deactivation, and extending catalyst lifetime. In some configurations, the vapor chambers provide effective thermal management without requiring additional heating or cooling sources, thereby reducing complexity and operating costs. Additionally, the vapor chambers provide enhanced thermal control during transient reactor operation.

[0021] Furthermore, the methods presented in this paper provide versatile reactor designs applicable to a variety of chemical processes, including the production of syngas and sustainable aviation fuels, ensuring optimal performance across diverse applications. The reactor designs are scalable to accommodate varying production capacities, ensuring consistent performance regardless of reactor size.

[0022] The terms and expressions used herein have the ordinary technical meanings that those skilled in the art would assign to them, unless otherwise specifically defined herein. Unless otherwise specified, the word “or” as used herein should be interpreted as having a disjunctive structure rather than a conjunctive structure. Unless otherwise specified herein, the terms “connection,” “fixation,” “attachment,” etc., refer both to direct connection, fixation, or attachment, and to indirect connection, fixation, or attachment through one or more intermediate components or features.

[0023] Unless the context clearly indicates otherwise, the singular forms “one,” “a,” and “the” all include plural meanings.

[0024] As used throughout this specification and claims, approximate language is applied to modify any quantitative representation that may vary permissibly without altering its underlying function. Therefore, values ​​modified by terms such as “approximately,” “approximately,” and “essentially” are not limited to specified precise values. In at least some instances, approximate language may correspond to the precision of the instrument used to measure the value, or to the precision of the method or machine used to construct or manufacture a component and / or system. For example, approximate language may refer to a margin of 10%.

[0025] The above and other interests may become clearer after a full review and study of the following detailed description.

[0026] Now refer to the attached diagram, Figure 1This is a simplified cross-sectional view of an exemplary reactor 100, compatible with many of these teachings. Reactor 100 includes a reactor vessel 102, a reactor core 104, an inlet 106, and an outlet 108. The inlet 106 is located at a first end 110 of the reactor vessel 102, and the outlet is located at a second end 112 of the reactor vessel 102. Figure 1 As shown, reactor 100 includes a generally cylindrical reactor vessel 102. It can be considered that... Figure 1 The exemplary reactor 102 shown is merely an example. In other exemplary embodiments, the reactor vessel may have other suitable configurations. In some examples, the reactor vessel 102 may include a rectangular or other polygonal cross-section. In some examples, the inlet 106 and outlet 108 may be located at any suitable location on the reactor vessel 102.

[0027] In operation, feed stream 114a flows through inlet 106, passes from the first end 110 through reactor core 104 to the second end 112, and outflow stream 114b (i.e., the post-reaction feed stream) exits through outlet 108. More specifically, feed stream 114a is introduced into reactor vessel 102 through inlet 106, which is fluidly connected (e.g., via a pipe) to feed supply device 116. Feed supply device 116 may include any suitable tank or component to store feed stream 114a. One or more heating units 118 may be operatively coupled to feed supply device 116 to heat feed stream 114a to a suitable temperature based on the intended application of reactor 100. For example, feed stream 114a may be heated to a temperature range of approximately 150 degrees Celsius to approximately 950 degrees Celsius. One or more heating units 118 may include any suitable heat source, such as a heat exchanger, preheater, etc.

[0028] The effluent stream 114b exits the reactor vessel 102 through an outlet 108 that is fluidly connected (e.g., via a pipe) to the product storage unit 120. The product storage unit 120 may include any suitable tank or component for storing the effluent stream 114b.

[0029] Feed stream 114a may include any suitable feedstock. For example, feedstock stream 114a may include hydrogen (H2), carbon dioxide (CO2), methane (CH4), or syngas (CO+H2). It is conceivable that reactor 100 can be used for a variety of chemical production applications, and the feedstock can be selected based on the desired application. In a preferred embodiment, reactor 100 can be used to convert hydrocarbon feedstocks into syngas (“syngas” is a mixture of carbon monoxide (CO) and hydrogen (H2)). In other embodiments, reactor 100 can be used for reverse water-gas shift reactions, Fischer-Tropsch reactions, hydrocracking, hydrogenation, methanol synthesis, methanol-to-olefins, olefin oligomerization, etc.

[0030] In some embodiments, reactor 100 includes a second inlet 122 and a second outlet 124. The second inlet 122 and the second outlet 124 may be arranged at any suitable location along reactor vessel 102. In operation, thermal management fluid 126 flows in through the second inlet 122, flows through reactor core 104 and / or its surroundings, and then exits through the second outlet 124. More specifically, thermal management fluid 126 is introduced into reactor vessel 102 through the second inlet 122, which is fluidly connected (e.g., via a pipe) to thermal management unit 128. Thermal management unit 128 may include any suitable tank, or alternatively, a heat exchanger, cooler, etc. One or more pumps 130 may be operatively coupled to thermal management unit 128 to control the flow rate of thermal management fluid 126.

[0031] Thermal management fluid 126 exits from reactor vessel 102 through second outlet 124. In some embodiments, second outlet 124 may be fluidly connected to second thermal management unit 132 (e.g., via a pipe). Thermal management fluid 126 can be any suitable fluid. Suitable fluids include, but are not limited to, air, nitrogen, carbon dioxide, helium, and argon. Second thermal management unit 132 may include any suitable tank, or alternatively, a heat exchanger, cooler, etc. In some forms, second inlet 122 and second outlet 124 may be fluidly connected to the same thermal management unit 128.

[0032] The thermal management fluid 126 may include any suitable heating or cooling medium to control the temperature of the reactor vessel 102. The thermal management fluid 126 may be selected based on the operating temperature of the desired application. For example, the thermal management fluid 126 may include water, steam, etc.

[0033] Figures 2 to 5 As shown Figure 1 Various embodiments of the reactor 100 are shown. It should be noted that, although... Figures 2 to 5 A reactor configuration with an axisymmetric region is shown, but any embodiment shown may include non-axisymmetric regions. In this regard, reactor cores or regions of rectangular, triangular, cylindrical, hexagonal, octagonal, irregular, or other shapes may be used.

[0034] refer to Figure 2 The diagram shows a two-dimensional cross-sectional view of the configuration of reactor 200. Reactor 200 includes at least two domains. More specifically, reactor 200 includes a first region 202 defining a reaction domain and a second region 204 defining a heat diffusion domain. The first region 202 and the second region 204 are in thermal communication, which allows temperature changes within the first region 202 to be spatially distributed over a relatively wide area through the second region 204.

[0035] The first region 202 (i.e., the reaction zone) includes a catalyst bed 206. In some forms, the catalyst bed 206 includes a packed bed of catalyst having a plurality of catalyst particles 208. The plurality of catalyst particles 208 may include any suitable catalyst. In one form, the plurality of catalyst particles 208 may include a nickel-based catalyst. However, it is conceivable that any suitable catalyst may be used, including but not limited to cobalt-based catalysts, iron-based catalysts, palladium and platinum catalysts, etc.

[0036] The second region 204 (i.e., the heat diffusion domain) includes one or more vapor chambers 210. Although Figure 2 A vapor chamber 210 is shown arranged adjacent to the catalyst bed 206, but it is conceivable that the second region 204 may include any suitable number of vapor chambers. Specific configurations of one or more vapor chambers 210 will be referenced. Figures 6-11 Describe it.

[0037] In addition, it can be considered that, although Figure 2 Only one first region 202 and one second region 204 are shown, but reactor 200 may include any suitable number of first and second regions. In some forms, one or more first regions 202 may be integrally formed with one or more second regions 204. More specifically, one or more first regions 202 and one or more second regions 204 may be manufactured as a single continuous core without seams, joints, or connections (e.g., the two regions cannot be physically separated). In other forms, one or more first regions 202 may be integrally nested and interwoven with one or more second regions 204. One or more first regions 202 and one or more second regions 204 integrally formed or integrally nested and interwoven may be manufactured by any suitable manufacturing process, including but not limited to additive manufacturing, machining, casting, or any other suitable technique.

[0038] During operation, the raw material flow (i.e., Figure 1 The feed stream 114 shown flows through the first region 202 and undergoes a reaction within the catalyst bed 206. As the feed stream undergoes the reaction, it can be gradually cooled as it flows through the reactor 200, creating a thermal gradient within the first region 202. Furthermore, the reaction may generate or absorb heat, thus creating a thermal gradient within the first region 202. For example, a thermal gradient may form between a hot zone 212 (i.e., where the temperature of the catalyst bed 206 increases) and a cold zone 214 (i.e., where the temperature of the catalyst bed 206 decreases). In some forms, the hot zone 212 may be located as follows: Figure 1 The reactor 100 shown is located near its first end 110, while the cold zone 214 may be located as follows: Figure 1 Near the second end 112 of the reactor 100 shown.

[0039] As described in more detail below, one or more vapor chambers 210 are operated using an evaporation-condensation cycle of a working fluid (not shown) maintained within the vapor chambers 210. The working fluid (not shown) is maintained in a saturated state, such that it coexists in liquid and vapor forms at saturated temperature and pressure. The saturated state allows for efficient internal phase change heat transfer, as the working fluid (not shown) absorbs heat to evaporate and releases heat to condense with minimal temperature change. In other words, one or more vapor chambers 210 diffuse heat within a first region 202 (e.g., between hot region 212 and cold region 214) through internal phase change heat transfer to reduce the thermal gradient within the first region 202. Therefore, one or more vapor chambers 210 maintain the catalyst bed 206 within an effective temperature range to achieve the desired reaction rate and product yield, thereby improving reactor efficiency. Advantageously, in some forms, one or more vapor chambers 210 can eliminate the need for additional heating or cooling sources by uniformly distributing the heat generated in the catalyst bed 206 during the reaction.

[0040] refer to Figure 3 The image shows a two-dimensional cross-sectional view of the configuration of reactor 300. Reactor 300 includes at least three domains. More specifically, reactor 300 includes a first region 302 defining a reaction domain, a second region 304 defining a heat diffusion domain, and a third region 306 defining a heat management domain. There is thermal communication between the first region 302, the second region 304, and the third region 306. In this configuration, temperature variations within the first region 302 are reduced by the second region 304, and the second region 304 can uniformly transfer or remove heat from the first region 302 via the third region 306.

[0041] The first region 302 (i.e., the reaction zone) includes a catalyst bed 308. In some forms, the catalyst bed 308 comprises a packed catalyst bed having multiple catalyst particles, such as... Figure 2 The diagram shows a plurality of catalyst particles 208. The plurality of catalyst particles may comprise any suitable catalyst. In one form, the plurality of catalyst particles may comprise a nickel-based catalyst. However, it is conceivable that any suitable catalyst may be used, including but not limited to cobalt-based catalysts, iron-based catalysts, palladium and platinum catalysts, etc.

[0042] The second region 304 (i.e., the heat diffusion domain) includes one or more vapor chambers 310. Although Figure 3 A steam chamber 310 is shown arranged adjacent to the first region 302, but it is conceivable that the second region 304 may include any suitable number of steam chambers. Specific configurations of one or more steam chambers 310 will be referenced. Figures 6 to 11 Describe it.

[0043] The third region 306 (i.e., the thermal management domain) includes a heating source or a cooling source, which includes thermal management fluids (such as...) Figure 1 The thermal management fluid 126 is shown. The temperature of the heating or cooling source may be spatially uniform within the third region 306, or it may be spatially non-uniform within the third region 306, exhibiting temperature variations. The thermal management fluid may include a heating medium or a cooling medium. In some forms, the third region 306 may include an inlet (e.g., Figure 1 The second inlet (122) and outlet (as shown) Figure 1 The second outlet 124 shown is connected to one or more conduits or passages in a fluid manner. "Heating medium" can be considered as a fluid with a temperature higher than that of the catalyst particles. For example, the temperature can be any suitable temperature for initiating, maintaining, or enhancing a catalytic reaction within the reactor. Similarly, "cooling medium" can be considered as a fluid with a temperature lower than that of the catalyst particles. For example, the temperature can be any suitable temperature for controlling, reducing, or maintaining thermal conditions within the reactor.

[0044] In addition, it can be considered that, although Figure 3 Only one first region 302, one second region 304, and one third region 306 are depicted, but reactor 300 may include any suitable number of first, second, or third regions. In some forms, one or more first regions 302, one or more second regions 304, and one or more third regions 306 may be integrally formed. More specifically, one or more first regions 302, one or more second regions 304, and one or more third regions 306 may be manufactured as a single continuous core without seams, joints, or connections (e.g., the three regions cannot be physically separated). In other forms, one or more first regions 302, one or more second regions 304, and one or more third regions 306 may be integrally nested and interwoven. One or more first regions 302, one or more second regions 304, and one or more third regions 306 that are integrally formed or integrally nested and interwoven may be manufactured by any suitable manufacturing process, including but not limited to additive manufacturing, machining, casting, or any other suitable technique.

[0045] like Figure 3 As shown, the second region 304 is located within the volume 312 between the first region 302 and the third region 306. It should be understood that "between" refers to a spatial relationship in which at least one boundary 314 of the second region 304 is adjacent to, in contact with, or thermally connected to the first region 302, and at least one boundary 316 of the second region 304 is adjacent to, in contact with, or thermally connected to the third region 306.

[0046] During operation, the raw material flow (such as...) Figure 1The feed stream 114 shown flows through the first region 302 and undergoes a reaction within the catalyst bed 308. As the feed stream undergoes the reaction, it can be gradually cooled as it flows through the reactor 300, creating a thermal gradient within the first region 302. Furthermore, the reaction may generate or absorb heat, forming a thermal gradient. For example, a thermal gradient may form between a hot zone 320 (i.e., where the temperature of the catalyst bed 308 increases) and a cold zone 322 (i.e., where the temperature of the catalyst bed 308 decreases). In some configurations, the hot zone 320 may be located as follows: Figure 1 The reactor 100 shown is located near its first end 110, while the cold zone 322 may be located as follows: Figure 1 Near the second end 112 of the reactor 100 shown.

[0047] As described in more detail below, one or more vapor chambers 310 are operated using an evaporation-condensation cycle of a working fluid (not shown) maintained within the vapor chambers 310. The working fluid (not shown) is maintained in a saturated state, such that it coexists in liquid and vapor forms at saturated temperature and pressure. The saturated state allows for efficient internal phase change heat transfer, as the working fluid (not shown) absorbs heat to evaporate and releases heat to condense with minimal temperature change. In other words, one or more vapor chambers 310 diffuse heat within a first region 302 (e.g., between hot and cold regions 322) via internal phase change heat transfer to minimize the thermal gradient within the first region 302. Therefore, one or more vapor chambers 310 maintain the catalyst bed 308 within an effective temperature range to achieve the desired reaction rate and product yield, thereby improving reactor efficiency.

[0048] Alternatively, one or more vapor chambers 310 may uniformly heat (i.e., heat the medium) or cool (i.e., cool the medium) the first region 302 via the third region 306 through internal phase change heat transfer. In this way, the first region 302 can be uniformly heated or cooled regardless of any local temperature gradient of the thermal management fluid within the third region 306.

[0049] refer to Figure 4 The diagram shows a two-dimensional cross-sectional view of the configuration of reactor 400. Reactor 400 can be configured with... Figure 3 The reactor core is configured in a substantially similar manner. As shown in the figure, reactor 400 includes at least three domains. More specifically, reactor 400 includes a first region 402 defining a reaction domain, a second region 404 defining a heat diffusion domain, and a third region 406 defining a heat management domain. The first region 402, the second region 404, and the third region 406 are thermally connected.

[0050] The first region 402 (i.e., the reaction zone) includes a catalyst bed 408. In some forms, the catalyst bed 408 comprises a packed catalyst bed having multiple catalyst particles, such as... Figure 2 The diagram shows multiple catalyst particles 208. These multiple catalyst particles may comprise any suitable catalyst. In one form, the multiple catalyst particles may comprise a nickel-based catalyst. However, it is contemplated that any suitable catalyst may be used, including but not limited to cobalt-based catalysts, iron-based catalysts, palladium and platinum catalysts, etc.

[0051] The second region 404 (i.e., the heat diffusion domain) includes one or more vapor chambers 410. Although Figure 4 A steam chamber 410 is depicted arranged adjacent to the first region 402, but it is conceivable that the second region 404 may include any suitable number of steam chambers. (See reference...) Figures 6-11 Describe the specific structure of one or more vapor chambers 410.

[0052] The third region 406 (i.e., the thermal management domain) includes a heating or cooling source, which includes thermal management fluids (such as...) Figure 1 The thermal management fluid 126 is shown. The temperature of the heating or cooling source may be spatially uniform within the third region 406, or alternatively, it may be spatially non-uniform within the third region 406, exhibiting temperature variations. The thermal management fluid may include a heating medium or a cooling medium. In some forms, the third region 406 may include an inlet (e.g., Figure 1 The second inlet (122) and outlet (as shown) Figure 1 The second outlet 124 shown is a fluid-connected conduit or passageway to one or more tubes or passages.

[0053] and Figure 3 Unlike the embodiment shown, the first region 402 is disposed within a volume 412 between the second region 404 and the third region 406. It should be understood that "between" refers to a spatial relationship in which at least one boundary 416 of the first region 402 is adjacent to, in contact with, or thermally connected to the second region 404, and at least one boundary 418 of the first region 402 is adjacent to, in contact with, or thermally connected to the third region 406.

[0054] As described in more detail below, one or more vapor chambers 410 are operated using an evaporation-condensation cycle of a working fluid (not shown) maintained within the vapor chambers 410. The working fluid (not shown) is maintained in a saturated state, such that it coexists in liquid and vapor forms at saturated temperature and pressure. The saturated state allows for efficient internal phase change heat transfer, as the working fluid (not shown) absorbs heat to evaporate and releases heat to condense with minimal temperature change. In this way, one or more vapor chambers 410 diffuse heat within a first region 402 via internal phase change heat transfer, thereby reducing the thermal gradient within the first region 402. Therefore, one or more vapor chambers 410 maintain the catalyst bed 408 within an effective temperature range to achieve the desired reaction rate and product yield, thus improving reactor efficiency.

[0055] In addition, the thermal management fluid (such as) in the third region 406 Figure 1 The heat management fluid 126 shown can heat (i.e., heat the medium) or cool (i.e., cool the medium) the first region 402. In this way, the thermal gradient formed in the catalyst bed 408 of the first region 402 can be smoothed by both the heat management fluid and one or more vapor chambers 410.

[0056] refer to Figure 5 The diagram shows a two-dimensional cross-sectional view of the configuration of reactor 500. Reactor 500 includes at least two domains. More specifically, reactor 500 includes a first region 502 defining a reaction domain and a second region 504 defining a thermal management domain.

[0057] The first region 502 (i.e., the reaction zone) includes a catalyst bed 506. In some forms, the catalyst bed 506 comprises a packed catalyst bed having multiple catalyst particles, for example... Figure 2 The diagram shows a plurality of catalyst particles 208. These catalyst particles may comprise any suitable catalyst. In one form, the catalyst particles may comprise a nickel-based catalyst. However, it is conceivable that any suitable catalyst may be used, including but not limited to cobalt-based catalysts, iron-based catalysts, palladium and platinum catalysts, etc.

[0058] The second region 504 (i.e., the thermal management domain) includes thermal management fluids (e.g., Figure 1 The heat management fluid 126 shown is a heating or cooling source. The temperature of the heating or cooling source may be spatially uniform within the third region 306, or alternatively, it may be spatially non-uniform within the third region 306, exhibiting temperature variations. The heat management fluid may include a heating medium or a cooling medium. In some forms, the third region 504 may include an inlet (e.g., Figure 1 The second inlet 122 shown) and outlet (e.g.) Figure 1One or more conduits or passages fluidly connected to the second outlet 124 (shown) are used to transfer heat to or remove heat from the catalyst bed 506.

[0059] It's worth considering, although Figure 5 Only one first region 202 and one second region 204 are shown, but reactor 500 may include any suitable number of first and second regions. In some forms, one or more first regions 502 may be integrally formed with one or more second regions 504. More specifically, one or more first regions 502 and one or more second regions 504 may be manufactured as a single continuous core without seams, joints, or connections (e.g., the two regions cannot be physically separated). In other forms, one or more first regions 502 may be integrally nested and interwoven with one or more second regions 504. As will be understood, integrally formed one or more first regions 502 and one or more second regions 504 allow for compact reactor geometries with high surface area to volume ratios, customizable three-dimensional shapes, and weight savings.

[0060] One or more first regions 502 and second regions 504 that are integrally formed or integrally nested and interwoven can be manufactured by any suitable manufacturing process, including but not limited to additive manufacturing, machining, casting or any other suitable technology.

[0061] Figures 6-11 Various embodiments of the steam chamber are shown. (See reference...) Figures 6-11 The described steam chamber may be as referenced. Figures 2-4 Examples of one or more steam chambers shown and described. Figures 2-4 The steam chamber in the embodiments may use any of the various embodiments of the steam chamber described below, or alternatively, a combination of various embodiments of the steam chamber. It should be noted that, referring to... Figures 6-11 Any of the various embodiments of the described steam chamber can be designed for one-dimensional, two-dimensional, or three-dimensional heat transfer. In this regard, the steam chamber can diffuse heat along a single axis or multiple axes of the reactor, as referenced... Figures 2-4 As shown and described.

[0062] refer to Figure 6The diagram shows a cross-sectional side perspective view of a cylindrical vapor chamber 600. The vapor chamber 600 includes a shell 602 defining an enclosed volume 604, and a wick structure 606. The shell 602 forms a sealed outer shell of the vapor chamber 600 (i.e., forms a sealed enclosure) and includes an evaporation section 612, a condenser section 614 at opposite ends of the evaporation section 612, and an adiabatic section 616 located between the evaporation section 612 and the condenser section 614. The shell 602 is filled with and retains working fluids 608, 610, which act as heat carriers for transferring thermal energy from the evaporation section 612 to the condenser section 614 via internal phase change heat transfer. The evaporation section 612 is connected to a heat source (e.g., such as...) Figure 2 The hot zone 212 shown is in thermal contact to allow the working fluids 608 and 610 to evaporate from the liquid phase 608 to the gas phase 610. The condenser section 614 is in contact with the radiator (e.g., such as...). Figure 2 The cold zone 214 shown is in thermal contact to condense the gas phase 610 of the working fluids 608 and 610 into the liquid phase 608.

[0063] The core structure 606 is attached to the inner surface 618 of the housing 602. The core structure 606 includes a porous medium, specifically a liquid phase 608, for transporting the working fluid between the condenser section 614 and the evaporator section 612 via capillary forces. The core structure 606 can be formed of any suitable core structure. Suitable core structures may include, but are not limited to, porous metal cores, fiber cores, grooved cores, sieve cores, foam cores, or composite cores.

[0064] The working fluids 608 and 610 can be any suitable fluid. The working fluids 608 and 610 can be selected based on thermal conductivity, latent heat of vaporization, compatibility, and stability. In one example, the working fluid may include pure water. In other examples, the working fluid may include ammonia, ethanol, etc.

[0065] In operation, heat is transferred (i.e., indicated by arrow 620) to the evaporation section 612 of the housing 602 (corresponding to a region with a relatively high local temperature) to cause the liquid phase 608 of the working fluid to evaporate. Subsequently, the vapor phase 610 of the working fluid carries the heat to the condenser section 614 (corresponding to a region with a relatively low local temperature). The vapor phase 610 of the working fluid is transported from the evaporation section 612 to the condenser section 614 by the pressure generated by the local pressure difference between the evaporation section 612 (higher pressure) and the condenser section 614 (lower pressure). When the vapor phase 610 of the working fluid condenses back into the liquid phase 608, heat is released through the condenser section 614 of the housing 602 (i.e., indicated by arrow 622). The liquid phase 608 of the working fluid (i.e., the condensate) is then recirculated back to the evaporation section 612 by gravity or capillary force to restart the evaporation-condensation cycle. It can be considered that the evaporation of the liquid phase 608 of the working fluid in the evaporation section 612 serves as a vapor mass source, while the condensation of the gaseous phase 610 of the working fluid in the condenser section 614 serves as a vapor mass sink. The vapor mass source and vapor mass sink generated by the relative heating of the evaporation section 612 (i.e., endothermic, indicated by arrow 620) and the cooling of the condenser section 614 (i.e., exothermic, indicated by arrow 622) generate the flow of the gaseous phase 610 of the working fluid.

[0066] In some embodiments, the vapor chamber 600 may be configured as a thermosiphon without a core structure 606. In this way, the vapor chamber 600 (e.g., thermosiphon) transfers the gaseous phase 610 of the working fluid from the evaporation section 612 to the condenser section 614 by pressure (e.g., a vapor mass source / trap). The liquid phase 608 of the working fluid (i.e., the condensate) is then recirculated back to the evaporation section 612 by acceleration (e.g., gravity) to restart the evaporation-condensation cycle.

[0067] refer to Figure 7 The diagram shows a cross-sectional perspective view of a planar vapor chamber 700. The vapor chamber 700 includes a housing 702 defining an enclosed volume 704, and a core structure 706. The housing 702 forms a sealed outer shell (i.e., a sealing enclosure) of the vapor chamber 700 and includes an evaporation section 712 and a condenser section 714 at opposite ends of the evaporation section 712. The housing 702 is filled with and retains working fluids 708 and 710, which act as heat carriers for transferring thermal energy from the evaporation section 712 to the condenser section 714 via internal phase change heat transfer. The evaporation section 712 is connected to a heat source (e.g., such as...). Figure 2 The hot zone 212 shown is in thermal contact to allow the working fluids 708 and 710 to evaporate from the liquid phase 708 to the gas phase 710. The condenser section 714 is in contact with the radiator (e.g., such as...). Figure 2The cold zone 214 shown is in thermal contact to condense the gas phase 710 of the working fluids 708 and 710 into the liquid phase 708.

[0068] The core structure 706 is attached to the inner surface 716 of the housing 702. The core structure 706 includes a porous medium to transport the liquid phase 708 of the working fluids 708, 710 between the condenser section 714 and the evaporator section 712 via capillary forces. The core structure 706 can be formed of any suitable core structure. Suitable core structures may include, but are not limited to, porous metal cores, fiber cores, grooved cores, sieve cores, foam cores, or composite cores.

[0069] The working fluids 708 and 710 can be any suitable fluid. The working fluids 708 and 710 can be selected based on thermal conductivity, latent heat of vaporization, compatibility, and stability. In one example, the working fluid may include pure water. In other examples, the working fluid may include ammonia, ethanol, etc.

[0070] In operation, heat is transferred (i.e., indicated by arrow 720) to the evaporation section 712 of the housing 702 to cause the liquid phase 708 of the working fluid to evaporate. Subsequently, the gaseous phase 710 of the working fluid carries the heat to the condenser section 714. When the gaseous phase 710 of the working fluid condenses back into the liquid phase 708 of the working fluid, the heat is released through the condenser section 714 of the housing 702 (i.e., indicated by arrow 722). The liquid phase 708 of the working fluid (i.e., the condensate) is then recirculated back to the evaporation section 712 by capillary force to restart the evaporation-condensation cycle.

[0071] refer to Figure 8 A cross-sectional view of a planar vapor chamber 800 is shown. The vapor chamber 800 may be an oscillating heat pipe. The vapor chamber 800 includes a housing 802 defining a closed volume 804 for holding working fluids 820, 824, and a sealed tortuous passage 806 (i.e., a sealed enclosure). The tortuous passage 806 has a first U-bend 808 at a first end 810 and a second U-bend 812 at a second end 814. In some forms, the first U-bend 808 defines an evaporation section 816, and the second U-bend 812 defines a condenser section 818. In other forms, the first U-bend 808 defines a condenser section 818, and the second U-bend 812 defines an evaporation section 816. In yet another form, different evaporation sections 816 and condenser sections 818 may be formed within a straight section of the tortuous passage 806. The evaporation section 816 is connected to a heat source (e.g., such as...) Figure 2 The hot zone 212 shown is in thermal contact to allow the working fluids 820 and 824 to evaporate from the liquid phase 820 to the gas phase 824. The condenser section 818 is in contact with the radiator (e.g., such as...). Figure 2The cold zone 214 shown is in thermal contact to condense the gas phase 824 of the working fluids 820 and 824 into the liquid phase 820.

[0072] The working fluids 820 and 824 can be any suitable fluid. The working fluids 820 and 824 can be selected based on thermal conductivity, latent heat of vaporization, compatibility, and stability. In one example, the working fluid may include water. In other examples, the working fluid may include ammonia, ethanol, etc.

[0073] The tortuous channel 806 is filled with liquid working fluid 820 through port 822. In operation, heat is transferred (i.e., indicated by arrow 826) to the evaporation section 816, causing at least a portion of the liquid phase 820 of the working fluid to evaporate into a vapor phase 824 of the working fluid. The vapor phase 824 of the working fluid then carries the heat to the condenser section 818. When the vapor phase 824 of the working fluid condenses back into the liquid phase 820 of the working fluid, the heat is released through the condenser section 818 (i.e., indicated by arrow 828). It is generally conceivable that the phase change between the liquid working fluid 820 and the vapor working fluid 824 causes oscillations due to pressure changes, which drive the liquid working fluid 820 and the vapor working fluid 824 within the tortuous channel 806.

[0074] In some forms, the vapor chamber 800 includes a sealed closed-loop tortuous channel 806, and the working fluids 820, 824 circulate in a continuous loop within the tortuous channel 806, driven by oscillations caused by pressure changes and phase changes between the liquid working fluid 820 and the gaseous working fluid 824. In other forms, the vapor chamber 800 includes a sealed open-loop tortuous channel 806 with two ends. The working fluids 820, 824 oscillate back and forth between the two ends of the tortuous channel 806.

[0075] refer to Figure 9 A cross-sectional view of a vapor chamber 900 is shown. The vapor chamber 900 may be a variable conductivity heat pipe. The vapor chamber 900 includes a shell 902 defining a closed volume 904, a core structure 906, and a reservoir 912 filled with a non-condensable gas 914. The shell 902 forms a sealed outer shell (i.e., a sealed enclosure) of the vapor chamber 900 and includes an evaporation section 916, a condenser section 918, and an adiabatic section 920 between the evaporation section 916 and the condenser section 918. The shell 902 is filled with and retains working fluids 908, 910, which act as heat carriers for transferring thermal energy from the evaporation section 916 to the condenser section 918 via internal phase change heat transfer. The evaporation section 916 is connected to a heat source (e.g., such as...) Figure 2 The hot zone 212 shown is in thermal contact to allow the working fluids 908 and 910 to evaporate from the liquid phase 908 to the gas phase 910. The condenser section 918 is in contact with the radiator (e.g., such as...). Figure 2The cold zone 214 shown is in thermal contact so that the gas phase 910 of the working fluids 908 and 910 condenses into the liquid phase 908.

[0076] The core structure 906 is attached to the inner surface 926 of the housing 902. The core structure 906 includes a porous medium to transport the liquid phase 908 of the working fluids 908, 910 between the condenser section 918 and the evaporator section 916 via capillary forces. The core structure 906 can be formed of any suitable core structure. Suitable core structures may include, but are not limited to, porous metal cores, fiber cores, grooved cores, sieve cores, foam cores, or composite cores.

[0077] The working fluids 908 and 910 can be any suitable fluid. The working fluids 908 and 910 can be selected based on thermal conductivity, latent heat of vaporization, compatibility, and stability. In one example, the working fluid may include pure water. In other examples, the working fluid may include ammonia, ethanol, etc.

[0078] In operation, heat is transferred (i.e., as indicated by arrow 922) to the evaporation section 916 of the housing 902, causing the liquid phase 908 of the working fluid to evaporate. The vapor phase 910 of the working fluid then carries the heat to the condenser section 918. When the vapor phase 910 of the working fluid condenses back into the liquid phase 908, the heat is released through the condenser section 918 of the housing 902 (i.e., indicated by arrow 924). The liquid phase 908 of the working fluid (i.e., the condensate) is then recirculated back to the evaporation section 916 by capillary action to restart the evaporation-condensation cycle.

[0079] During operation, an interface 932 is formed between the gaseous working fluid 910 and the non-condensable gas 914 to define an active region 934 and an inactive region 936 of the condenser section 918, in which the gaseous working fluid 910 condenses. The position of the interface 932 shifts based on the temperature in the evaporation section 916 and the vapor pressure in the enclosed volume 904. For example, as the temperature of the evaporation section 916 increases, the vapor pressure in the enclosed volume 904 increases, and the interface 932 shifts toward the second end 928 (i.e., the non-condensable gas 914 occupies a smaller portion of the condenser section 918). Thus, an active region 934 is added in the condenser section 918 to enhance heat dissipation in the vapor chamber 900. Conversely, as the temperature of the evaporation section 916 decreases, the vapor pressure in the enclosed volume 904 decreases, and the interface 932 shifts toward the first end 930 (i.e., the non-condensable gas 914 occupies a larger portion of the condenser section 918). Therefore, the active region 934 is reduced in the condenser section 918 to decrease the conductivity of the vapor chamber 900. In this way, heat transfer can be selectively controlled (i.e., increased, decreased, or shut off) by means of a reservoir 912 filled with a non-condensable gas 914. The non-condensable gas may include, but is not limited to, nitrogen, helium, argon, or carbon dioxide.

[0080] refer to Figure 10A and Figure 10B A cross-sectional view of a vapor chamber 1000 is shown. The vapor chamber 1000 may be a thermal diode heat pipe. The vapor chamber 1000 includes a housing 1002 defining an enclosed volume 1004, a core structure 1006, and a reservoir 1008. The housing 1002 forms a sealed outer shell (i.e., a sealed enclosure) of the vapor chamber 1000 and includes an evaporation section 1010, a condenser section 1012, and an insulating section 1014 between the evaporation section 1010 and the condenser section 1012. The housing 1002 is filled with and holds working fluids 1016 and 1018, which act as heat carriers for transferring thermal energy from the evaporation section 1010 to the condenser section 1012 via internal phase change heat transfer. The evaporation section 1010 is connected to a heat source (e.g., such as...) Figure 2 The hot zone 212 shown is in thermal contact with the working fluids 1016 and 1018, causing the liquid phase 1016 to evaporate into the gas phase 1018. The condenser section 1012 is in thermal contact with the radiator (e.g., such as...). Figure 2 The cold zone 214 shown is in thermal contact to condense the gas phase 1018 of the working fluid into the liquid phase 1016.

[0081] The core structure 1006 is attached to the inner surface 1020 of the housing 1002. The core structure 1006 includes a porous medium to transport the liquid phase 1016 of the working fluids 1016, 1018 between the condenser section 1012 and the evaporator section 1010 via capillary forces. The core structure 1006 can be formed of any suitable core structure. Suitable core structures may include, but are not limited to, porous metal cores, fiber cores, grooved cores, sieve cores, foam cores, or composite cores.

[0082] The working fluids 1016 and 1018 can be any suitable fluid. The working fluids 1016 and 1018 can be selected based on thermal conductivity, latent heat of vaporization, compatibility, and stability. In one example, the working fluid may include pure water. In other examples, the working fluid may include ammonia, ethanol, etc.

[0083] In operation, heat is transferred (i.e., as indicated by arrow 1022) to the evaporation section 1010 of the housing 1002, causing the liquid phase 1016 of the working fluid to evaporate. The vapor phase 1018 of the working fluid then carries the heat to the condenser section 918. When the vapor phase 1018 of the working fluid condenses back into the liquid phase 1016, the heat is released through the condenser section 1012 of the housing 1002 (i.e., indicated by arrow 1024). The liquid phase 1016 of the working fluid (i.e., the condensate) is then recirculated back to the evaporation section 1010 by capillary action to restart the evaporation-condensation cycle.

[0084] In normal operation, the liquid phase 1016 of the working fluid (i.e., the condensate) is recirculated to the evaporation section 1010 via the capillary force of the core structure 1006 to restart the evaporation-condensation cycle. For example... Figure 10A As shown, the reservoir 1008 is empty during normal operation. However, when the condenser section 1012 becomes hotter than the evaporator section 1010, the gaseous phase 1018 of the working fluid flows back to the evaporator section 1010 and condenses back into the liquid phase 1016 of the working fluid. More specifically, as Figure 10B As shown, the gaseous phase 1018 of the working fluid flows into the reservoir 1008 and condenses back into the liquid phase 1016 of the working fluid. Due to the isolation of the core structure 1006 within the reservoir 1008, the liquid phase 1016 of the working fluid (i.e., the condensate) is trapped within the reservoir 1008, thereby suppressing reverse heat flow. Therefore, the vapor chamber 1000 provides unidirectional heat transfer to enable precise thermal conditioning and control of the reactor performance.

[0085] refer to Figure 11The image shows a cross-sectional view of a vapor chamber 1100. The vapor chamber 1100 may be a loop heat pipe. The vapor chamber 1100 includes an evaporation section 1102, a condenser section 1104, a vapor pipe 1106, and a liquid pipe 1108. The evaporation section 1102 includes a sealing shell 1110, a liquid passage 1114, a reservoir 1116, a vapor passage 1118, and a core structure 1120. The sealing shell forms a sealed outer shell of the vapor chamber 1100 (i.e., a sealing enclosure) to retain the liquid phase 1112 of the working fluid. The liquid passage 1114 is disposed inside the evaporation section 1102, and the vapor passage 1118 is disposed outside the evaporation section 1102. The core structure 1120 is disposed between the liquid passage 1114 and the vapor passage 1118.

[0086] Evaporation section 1102 and heat source (such as Figure 2 The shown hot zone 212 is in thermal contact. The condenser section 1104 is in contact with the radiator (e.g., Figure 2 The cold zone 214 shown is in thermal contact. During operation, heat is transferred from a heat source (such as...) Figure 2 The heat transfer zone 212 (shown as arrow 1126) is transferred to the core structure 1120, causing the liquid phase 1112 of the working fluid to evaporate from the surface 1124 of the core structure 1120. As the liquid phase 1112 of the working fluid evaporates from the surface 1124, the core structure 1120 draws additional liquid phase working fluid 1112 from the reservoir 1116 to the surface 1124 via capillary force. The gas phase 1122 of the working fluid flows under pressure through the vapor passage 1118 into the vapor pipe 1106 and flows to the condenser section 1104. The gas phase 1122 of the working fluid flows into the condenser section 1104 and releases heat (i.e., as arrow 1128) to the radiator (such as...) as the gas phase 1122 of the working fluid condenses back into the liquid phase 1112 of the working fluid. Figure 2 The cold zone 214 is shown. The liquid phase 1112 of the working fluid (i.e., the condensate) flows back to the evaporation section 1102 through the liquid pipe 1108 to restart the evaporation-condensation cycle.

[0087] The working fluids 1112 and 1122 can be any suitable fluid. The working fluids 1112 and 1122 can be selected based on thermal conductivity, latent heat of vaporization, compatibility, and stability. In one example, the working fluid may include pure water. In other examples, the working fluid may include ammonia, ethanol, etc.

[0088] The core structure 1006 includes a porous medium to transport the liquid phase 1112 of the working fluid between the reservoir 1116 and the liquid channel 1114 to the surface 1124 of the core structure 1120. The core structure 1006 can be formed of any suitable core structure. Suitable core structures may include, but are not limited to, porous metal cores, fiber cores, grooved cores, sieve cores, foam cores, or composite cores.

[0089] Refer to Figure 12 ( Figure 12A and Figure 12B (This shows another embodiment of the configuration of reactor 1200.) Figure 12A This is a three-dimensional view of part of the internal structure of reactor 1200. Figure 12B It shows the formation Figure 12A A three-dimensional unit cell diagram of reactor 1200. These unit cells are designed to optimize the integration and function of the various domains of reactor 1200.

[0090] like Figure 12A As shown, reactor 1200 includes a compact solid body 1202 defining three domains. More specifically, the compact solid body 1202 includes a first region 1204 defining a catalyst domain, a second region 1206 defining a thermal diffusion domain, and a third region 1208 defining a thermal management domain. The first region 1204, and therefore the catalyst domain, maintains a similar shape and profile throughout reactor 1200. The second region 1206, and therefore the thermal diffusion domain, maintains a similar shape and profile throughout reactor 1200. The third region 1208, and therefore the thermal management domain, maintains a similar shape and profile throughout reactor 1200. While the cross-sectional shape of each region is typically depicted as triangular, it is contemplated that each region may have any suitable cross-sectional shape, including rectangular, circular, elliptical, or any regular or irregular geometric profile.

[0091] Region 1204, Region 1206, and Region 1208 are formed as a single entity. For example... Figure 12A As shown, the second region 1206 (i.e., the heat diffusion domain) surrounds the first region 1204 (i.e., the catalyst domain). Similarly, the third region 1208 (i.e., the thermal management domain) surrounds the second region 1206 (i.e., the heat diffusion domain). In this arrangement, the first region 1204, the second region 1206, and the third region 1208 are nested and intertwined. In other words, the second region 1206 is sandwiched between the first region 1204 and the third region 1208, providing integrated thermal management control. This nested configuration provides efficient heat transfer and thermal regulation within the reactor 1200.

[0092] The integrally formed reactor 1200 can be manufactured by any suitable manufacturing process, including but not limited to additive manufacturing, machining, casting, or any other suitable technology. In one example, additive manufacturing can be used to precisely control the geometry of different domains and the integration, thereby improving the overall performance and efficiency of the reactor.

[0093] The first region 1204 (i.e., the reaction zone) includes the catalyst bed, for example... Figure 2 The catalyst bed 206 is shown. In some forms, the catalyst bed includes components having, for example... Figure 2 The catalyst packed bed shown comprises multiple catalyst particles 208. The multiple catalyst particles may include any suitable catalyst based on the specific chemical reaction and process used in the reactor. In one form, the multiple catalyst particles may include a nickel-based catalyst. However, any suitable catalyst may be considered, including but not limited to cobalt-based catalysts, iron-based catalysts, palladium and platinum catalysts, etc.

[0094] The second region 1206 (i.e., the thermal diffusion domain) includes one or more vapor chambers, as referenced. Figures 6-11 As shown and described. It is conceivable that the second region 1206 may include any suitable number or type of vapor chambers to reduce the thermal gradient formed due to the reaction or the heating / cooling flow in the third region 1208. As described above, the vapor chambers operate via an evaporation-condensation cycle to provide a uniform heat distribution to the first region 1204.

[0095] The third region 1208 (i.e., the thermal management domain) includes the thermal management fluid. Depending on the reactor operation requirements, the thermal management fluid may include a heating medium or a cooling medium. In some forms, the third region 1208 defines a fluid connection to an inlet (i.e., such as...). Figure 1 The second inlet 122 and outlet (i.e., as shown) are shown. Figure 1 The conduit or passage of the second outlet 124 shown is used to transfer heat to or remove heat from the first region 1204 via the second region 1206 for precise thermal conditioning and optimal reactor performance.

[0096] It can be considered, although Figure 12A and Figure 12B The first region 1204, the second region 1206, and the third region 1208 are depicted, but reactor 1200 may include any suitable number of regions and / or domains. In some forms, reactor 1200 may have two integrally formed domains, including the first region 1204 (i.e., the reaction domain) and the second region 1206 (i.e., the heat diffusion domain). In other forms, reactor 1200 may include four or more integrally formed domains or regions. Refer to Figure 13 (i.e., Figure 13A , Figure 13B and Figure 13C (This shows another embodiment of reactor 1300). Figure 13A A perspective view of reactor 1300 is shown. Figure 13B A cross-sectional view of reactor 1300 is shown. Figure 13C A cross-sectional top view of reactor 1300 is shown.

[0097] In the embodiment shown in FIG13, the exemplary reactor 1300 may be a shell-and-tube reactor. Reactor 1300 includes a reactor vessel 1302, a reactor core 1304, a plurality of tubes 1306, and a plurality of steam chambers 1308. Other components of reactor 1300 include an inlet 1312 and an outlet 1314, a first tube sheet 1320 adjacent to a first end 3122 of reactor vessel 1302, a second tube sheet 1324 adjacent to a second end 1326 of reactor vessel 1302, and one or more baffles 1328 positioned within reactor core 1304.

[0098] Multiple tubes 1306 include a catalyst 1310. The catalyst 1310 is distributed within the multiple tubes 1306 and is selected based on the desired chemical reaction. The catalyst 1310 may be in the form of particles, beads, or a coated surface. In one form, the catalyst 1310 may include a nickel-based catalyst. However, any suitable catalyst may be considered, including but not limited to cobalt-based catalysts, iron-based catalysts, palladium and platinum catalysts, etc.

[0099] Multiple steam chambers 1308 may include reference Figures 6-11 Any one or more combinations of various vapor chambers shown and described. As discussed in more detail above, the multiple vapor chambers 1308 are operated by using an evaporation-condensation cycle of a working fluid (not shown) held within the multiple vapor chambers 1308. In other words, one or more vapor chambers 1308 dissipate heat through internal phase change heat transfer to minimize the thermal gradient formed in the catalyst 1310 and maintain the catalyst 1310 within an effective temperature range to improve reaction efficiency.

[0100] A first tube sheet 1320 and a second tube sheet 1324 support a plurality of tubes 1306 and a plurality of steam chambers 1308. The plurality of tubes 1306 extend axially between the first tube sheet 1320 and the second tube sheet 1324. Similarly, the plurality of steam chambers 1308 extend axially between the first tube sheet 1320 and the second tube sheet 1324. In some configurations, the plurality of tubes 1306 and the plurality of steam chambers 1308 are arranged in parallel configuration within a reactor core 1304 between the first tube sheet 1320 and the second tube sheet 1324.

[0101] like Figure 13A and Figure 13C As shown, multiple steam chambers 1308 are distributed around multiple tubes 1306. Additionally, as... Figure 13BAs shown, a plurality of vapor chambers 1308 are arranged within a plurality of tubes 1306 (i.e., extending through the catalyst 1310). Although the plurality of vapor chambers 1308 are shown as positioned around and through the plurality of tubes 1306, it is conceivable that the plurality of tubes 1306 and the plurality of vapor chambers 1308 may be arranged in a variety of configurations within the reactor vessel 1302. In some forms, the plurality of vapor chambers 1308 (or a single vapor chamber) may be positioned only around the plurality of tubes 1306. In other forms, the plurality of vapor chambers 1308 may be arranged only within the plurality of tubes 1306. In some still forms, the plurality of vapor chambers 1308 may be arranged around the plurality of tubes 1306 and within at least one of the plurality of tubes 1306.

[0102] Further aspects of this disclosure are provided by the subject matter of the following clauses:

[0103] A reactor comprising: one or more first regions defining a reaction domain and including a catalyst bed; and one or more second regions thermally connected to the one or more first regions, the one or more second regions defining a thermal diffusion domain and including one or more vapor chambers.

[0104] The reactor according to any of the preceding items further includes one or more third regions, the one or more third regions defining a thermal management region and including a thermal management fluid, the one or more third regions being in thermal communication with the one or more first regions and / or the one or more second regions.

[0105] According to any of the preceding items, in the reactor, a corresponding second region of the one or more second regions is disposed in the volume between a corresponding first region of the one or more first regions and a corresponding third region of the one or more third regions.

[0106] According to any of the preceding items, in the reactor, a corresponding first region of the one or more first regions is disposed in the volume between a corresponding second region of the one or more second regions and a corresponding third region of the one or more third regions.

[0107] According to any of the preceding items, the reactor wherein the thermal management fluid includes a heating medium or a cooling medium to control the temperature of the one or more first regions or the one or more second regions.

[0108] The reactor according to any of the preceding items, wherein each steam chamber includes a sealed enclosure defining a closed volume to maintain the working fluid in a saturated state.

[0109] The reactor according to any of the preceding items, wherein each steam chamber is configured to diffuse heat in the one or more first regions through an internal phase change of the working fluid within the working fluid.

[0110] According to any of the preceding claims, the reactor comprising one or more vapor chambers includes a sealed enclosure defining a closed volume to maintain the working fluid at saturation, wherein the sealed enclosure includes one or more evaporation sections absorbing heat from the one or more first regions and one or more condenser sections releasing heat to the one or more first regions.

[0111] According to any of the preceding claims, the reactor wherein the one or more vapor chambers include a porous core attached to the inner surface of the sealed enclosure, the porous core being configured to transfer the working fluid between the condenser section and the evaporation section by capillary force.

[0112] According to any of the preceding items, the reactor wherein the one or more vapor chambers are configured to transfer the working fluid between the evaporation section and the condenser section by pressure.

[0113] According to any of the preceding items, the reactor wherein the one or more vapor chambers are configured to transfer the working fluid between the evaporation section and the condenser section by an accelerating force.

[0114] According to any of the preceding items, the reactor, wherein the one or more vapor chambers further include non-condensable gas in the enclosed volume of the sealed enclosure.

[0115] According to any of the preceding claims, in the reactor, wherein the one or more steam chambers include a thermal diode heat pipe, the thermal diode heat pipe including a sealed enclosure and a reservoir, the sealed enclosure defining a closed volume to maintain the working fluid at saturation, and the reservoir for trapping the working fluid for unidirectional heat transfer.

[0116] According to any of the preceding claims, the reactor wherein the one or more vapor chambers include an oscillating heat pipe, the oscillating heat pipe including a sealed enclosure and a tortuous channel, the sealed enclosure defining a closed volume, and the tortuous channel being filled with a saturated working fluid.

[0117] According to any of the preceding items, the reactor, wherein the one or more vapor chambers comprise a loop heat pipe or a capillary pumped loop heat pipe.

[0118] A reactor comprising: one or more first regions defining a reaction domain and including a catalyst bed; and one or more second regions thermally connected to the one or more first regions, the one or more second regions defining a thermal diffusion domain and including one or more vapor chambers; wherein the one or more first regions and the one or more second regions are integrally formed.

[0119] The reactor according to any of the preceding items further includes one or more third regions, the one or more third regions defining a thermal management region and including a thermal management fluid, the one or more third regions being integrally formed with the one or more first regions and the one or more second regions.

[0120] According to any of the preceding items, in the reactor, a corresponding second region of the one or more second regions is disposed in the volume between a corresponding first region of the one or more first regions and a corresponding third region of the one or more third regions.

[0121] According to any of the preceding items, in the reactor, a corresponding first region of the one or more first regions is disposed in the volume between a corresponding second region of the one or more second regions and a corresponding third region of the one or more third regions.

[0122] A reactor includes: one or more first regions defining a reaction domain and including a catalyst bed; and one or more second regions in thermal communication with the one or more first regions, the one or more second regions defining a thermal management region and including a thermal management fluid; wherein the one or more first regions and the one or more second regions are integrally formed.

Claims

1. A reactor, characterized in that, include: One or more first regions, the one or more first regions defining a reaction domain and including a catalyst bed; as well as One or more second regions, which are in thermal communication with the one or more first regions, and which define a thermal diffusion domain and include one or more vapor chambers.

2. The reactor according to claim 1, characterized in that, It further includes one or more third regions, which define a thermal management region and include a thermal management fluid, and the one or more third regions are in thermal communication with the one or more first regions and / or the one or more second regions.

3. The reactor according to claim 2, characterized in that, The respective second region of the one or more second regions is disposed in the volume between the respective first region of the one or more first regions and the respective third region of the one or more third regions.

4. The reactor according to claim 2, characterized in that, The respective first region of the one or more first regions is disposed in the volume between the respective second region of the one or more second regions and the respective third region of the one or more third regions.

5. The reactor according to claim 2, characterized in that, The thermal management fluid includes a heating medium or a cooling medium to control the temperature of the one or more first regions or the one or more second regions.

6. The reactor according to claim 1, characterized in that, Each vapor chamber includes a sealed enclosure that defines an enclosed volume to keep the working fluid saturated within it.

7. The reactor according to claim 1, characterized in that, The one or more vapor chambers include a sealed enclosure defining a closed volume to maintain the working fluid at saturation, wherein the sealed enclosure includes one or more evaporation sections that absorb heat from the one or more first regions and one or more condenser sections that release heat to the one or more first regions.

8. The reactor according to claim 7, characterized in that, The one or more vapor chambers include a porous core attached to the inner surface of the sealed enclosure, the porous core being configured to transfer the working fluid between the one or more condenser sections and the one or more evaporation sections by capillary force.

9. The reactor according to claim 7, characterized in that, The one or more vapor chambers are configured to transfer the working fluid between the one or more evaporation sections and the one or more condenser sections by pressure.

10. The reactor according to claim 7, characterized in that, The one or more vapor chambers are configured to transfer the working fluid between the one or more evaporation sections and the one or more condenser sections by means of an accelerating force.

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